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USER INSTRUCTIONS

IDP HPX-H & HPX-MP Installation


centrifugal pumps
Operation
Single stage, single suction, radially split volute type Maintenance
centrifugal pumps

PCN=87900021-06/14 (E) Original instructions

These instructions must be read prior to installing,


operating, using and maintaining this equipment.
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

CONTENTS
PAGE

CONTENTS ............................................................... 2 6.5 Tools required .................................................33


1 INTRODUCTION AND SAFETY ............................ 4 6.6 Fastener torques ............................................33
1.1 General ........................................................... 4 6.7 Disassembly ...................................................35
1.2 CE marking and approvals............................... 4 6.8 Examination of parts .......................................37
1.3 Disclaimer ........................................................ 4 6.9 Assembly ........................................................38
1.4 Copyright .......................................................... 4 7 FAULTS; CAUSES AND REMEDIES ....................41
1.5 Duty conditions ................................................ 4
1.6 Safety ............................................................... 5 8 PARTS LIST AND DRAWINGS ............................44
1.7 Nameplate and safety labels............................ 8 9 CERTIFICATION ...................................................57
1.8 Specific machine performance ......................... 8
1.9 Noise level........................................................ 9 10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ........................................................57
2 TRANSPORT AND STORAGE ............................ 10 10.1 Supplementary User Instruction manuals ....57
2.1 Consignment receipt and unpacking.............. 10 10.3 Additional sources of information .................57
2.2 Handling ......................................................... 10
2.3 Lifting.............................................................. 10 NOTES: ....................................................................58
2.4 Storage........................................................... 10
2.5 Recycling and end of product life ................... 12
3 PUMP DESCRIPTION .......................................... 12
3.1 Configurations ................................................ 12
3.2 Nomenclature ................................................. 12
3.3 Design of major parts ..................................... 13
3.4 Performance and operating limits .................. 14
4 INSTALLATION ..................................................... 15
4.1 Location.......................................................... 15
4.2 Part assemblies ............................................. 15
4.3 Foundation .................................................... 15
4.4 Grouting ......................................................... 17
4.6 Piping ............................................................ 20
4.7 Final shaft alignment check ........................... 22
4.8 Electrical connections .................................... 22
4.9 Protection systems ......................................... 22
5 COMMISSIONING, START-UP, OPERATION AND
SHUTDOWN .................................................... 23
5.1 Pre-commissioning procedure ....................... 23
5.2 Pump Lubricants ............................................ 27
5.3 Direction of rotation ....................................... 28
5.4 Guarding ....................................................... 28
5.5 Priming and auxiliary supplies ...................... 28
5.6 Starting the pump.......................................... 29
5.7 Operating checks .......................................... 29
5.8 Normal Start Up ............................................. 30
5.9 Stopping the pump ......................................... 31
5.10 Hydraulic, mechanical and ........................... 31
electrical duty ....................................................... 31
6 MAINTENANCE.................................................... 31
6.1 General .......................................................... 31
6.2 Maintenance schedule ................................... 32
6.3 Spare parts..................................................... 33
6.4 Recommended spares (according to API) ..... 33

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

INDEX
PAGE PAGE
Additional sources (10.3) ......................................... 56 Recycling (2.5) .........................................................12
Alignment of shafting (see 4.5, 4.7 and 4.3) Replacement parts (see 6.3 and 6.4) ...................... 33
Assembly (6.9) ......................................................... 38 Running the pump (5.6) ...........................................29
ATEX marking (1.6.4.2) ............................................. 7 Safety action (1.6.3) ...................................................5
CE marking and approvals (1.2) ................................ 4 Safety markings (1.6.1) ..............................................5
Certification (9) ........................................................ 56 Safety, protection systems (see 1.6 and 4.9)
Change notes (10.2) ................................................ 56 Sectional drawings (8) ..............................................43
Clearances (see 6.9) ............................................... 38 Sound level (see 1.9, Noise level)..............................9
Commissioning and operation (see 5) ..................... 23 Sources, additional information (10.3) .....................56
Compliance, ATEX (1.6.4.1) ...................................... 6 Spare parts (6.3) ......................................................33
Configurations (3) .................................................... 12 Specific machine performance (1.8) ..........................8
Copyright (1.4) ........................................................... 4 Starting the pump (5.6) ............................................29
Design of major parts (3.3) ...................................... 13 Stop/start frequency (5.7.5) ......................................30
Direction of rotation (5.3) ......................................... 28 Stopping and shutdown (5.9) ...................................31
Disassembly (6.7) .................................................... 35 Storage, pump (2.4) .................................................10
Disclaimer (1.3).......................................................... 4 Storage, spare parts (6.3.2) .....................................33
Dismantling (see 6.7, Disassembly) ........................ 35 Supplementary manuals or information sources......57
Drawings (8) ............................................................ 43 Tools required (6.5) ..................................................33
Duty conditions (1.5) .................................................. 4 Torques for fasteners (6.6) .......................................33
Electrical connections (4.8) ..................................... 22 Trouble-shooting (see 7) ..........................................41
End of product life (2.5) ........................................... 12 Vibration (5.7.5) ........................................................30
Examination of parts (6.8) ....................................... 37 Warning labels (1.7.2) ................................................8
Fastener torques (6.6) ............................................. 33
Faults; causes and remedies (7) ............................. 41
General assembly drawings (see 8.15) ................... 56
Grouting (4.4)........................................................... 17
Guarding (5.4).......................................................... 28
Handling (2.2) .......................................................... 10
Hydraulic, mechanical and electrical duty (5.10) ..... 31
Impeller clearance (6.9) ........................................... 38
Inspection (6.2) ........................................................ 32
Installation (4) .......................................................... 15
Lifting (2.3) ............................................................... 10
Location (4.1) ........................................................... 15
Lubrication (see 5.1.1, 5.2 and 6.2.3)
Lubrication schedule (see 5.2, Pump lubricants) .... 27
Maintenance (6) ....................................................... 31
Maintenance schedule (6.2) .................................... 32
Name nomenclature (3.2) ........................................ 12
Nameplate (1.7.1) ...................................................... 8
Operating limits (3.4) ............................................... 14
Ordering spare parts (6.3.1) .................................... 33
Part assemblies (4.2) ............................................... 15
Parts lists (8) ............................................................ 43
Performance (3.4) .................................................... 14
Piping (4.6) .............................................................. 20
Pre-commissioning (5.1) .......................................... 23
Protection systems (4.9) .......................................... 22
Priming and auxiliary supplies (5.5)......................... 28
Reassembly (see 6.9, Assembly) ............................ 38
Receipt and unpacking (2.1).................................... 10
Recommended fill quantities (see 5.2.2) ................. 28
Recommended oil lubricants (5.2.1) ........................ 27
Recommended spares (6.4) .................................... 33

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

1 INTRODUCTION AND SAFETY Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
1.1 General machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
These Instructions must always be kept incorporates information relevant to these Directives
close to product's operating location or directly and Approvals. To confirm the Approvals applying
with the product. and if the product is CE marked, check the serial
number plate markings and the Certification, see
Flowserve's products are designed, developed and section 9, Certification.
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great care
and commitment to continuous quality control, utilising 1.3 Disclaimer
sophisticated quality techniques, and safety Information in these User Instructions is believed
requirements. to be reliable. In spite of all the efforts of
Flowserve to provide sound and all necessary
Flowserve is committed to continuous quality information the content of this manual may appear
improvement and being at service for any further insufficient and is not guaranteed by Flowserve as
information about the product in its installation and to its completeness or accuracy.
operation or about its support products, repair and Flowserve manufactures products to exacting
diagnostic services. International Quality Management System Standards
as certified and audited by external Quality
These instructions are intended to facilitate Assurance organisations. Genuine parts and
familiarization with the product and its permitted use. accessories have been designed, tested and
Operating the product in compliance with these incorporated into the products to help ensure
instructions is important to help ensure reliability in continued product quality and performance in use. As
service and avoid risks. The instructions may not take Flowserve cannot test parts and accessories sourced
into account local regulations; ensure such from other vendors the incorrect incorporation of such
regulations are observed by all, including those parts and accessories may adversely affect the
installing the product. Always coordinate repair performance and safety features of the products. The
activity with operations personnel, and follow all plant failure to properly select, install or use authorised
safety requirements and applicable safety and health Flowserve parts and accessories is considered to be
laws/regulations. misuse. Damage or failure caused by misuse is not
covered by Flowserve's warranty. In addition, any
These instructions must be read prior to modification of Flowserve products or removal of
installing, operating, using and maintaining the original components may impair the safety of these
equipment in any region worldwide. The products in their use.
equipment must not be put into service until all the
conditions relating to safety, noted in the 1.4 Copyright
instructions, have been met. Failure to follow and All rights reserved. No part of these instructions may
apply the present user instructions is considered be reproduced, stored in a retrieval system or
to be misuse. Personal injury, product damage, transmitted in any form or by any means without prior
delay or failure caused by misuse are not covered permission of Flowserve Corporation.
by the Flowserve warranty.
1.5 Duty conditions
1.2 CE marking and approvals This product has been selected to meet the
It is a legal requirement that machinery and specifications of your purchaser order. The
equipment put into service within certain regions of acknowledgement of these conditions has been sent
the world shall conform with the applicable CE separately to the Purchaser. A copy should be kept
Marking Directives covering Machinery and, where with these instructions.
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive The product must not be operated beyond
(PED) and Equipment for Potentially Explosive the parameters specified for the application. If
Atmospheres (ATEX). there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

If the conditions of service on your purchase order are Always co-ordinate repair activity with operations and
going to be changed (for example liquid pumped, health and safety personnel, and follow all plant safety
temperature or duty) it is requested that the user seeks requirements and applicable safety and health laws
Flowserves written agreement before start up. and regulations.

1.6 Safety 1.6.3 Safety action

1.6.1 Summary of safety markings This is a summary of conditions and actions to


These user instructions contain specific safety help prevent injury to personnel and damage to
markings where non-observance of an instruction the environment and to equipment. For products
would cause hazards. The specific safety markings used in potentially explosive atmospheres section
are: 1.6.4 also applies.

This symbol indicates electrical safety PREVENT EXCESSIVE EXTERNAL


instructions where non-compliance will involve a high PIPE LOAD
risk to personal safety or the loss of life. Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
This symbol indicates safety instructions where in writing, so that their force, due to internal pressure,
non-compliance would affect personal safety and acts on the pump flange.
could result in loss of life.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, start-up, operation
This symbol indicates hazardous and toxic and shutdown.)
fluid safety instructions where non-compliance would
affect personal safety and could result in loss of life. START THE PUMP WITH OUTLET
VALVE PART OPENED
This symbol indicates safety (Unless otherwise instructed at a specific point in the
instructions where non-compliance will involve some user instructions.)
risk to safe operation and personal safety and would This is recommended to minimise the risk of
damage the equipment or property. overloading and damaging the pump and motor at full
or zero flow. Pumps may be started with the valve
This symbol indicates explosive atmosphere further open only on installations where this situation
marking according to ATEX. It is used in safety cannot occur. The pump outlet control valve may
instructions where non-compliance in the hazardous need to be adjusted to comply with the duty following
area would cause the risk of an explosion. the run-up process. (See section 5, Commissioning
start-up, operation and shutdown.)
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry NEVER RUN THE PUMP DRY
cloth; ensure cloth is damp. It is used where non-
compliance in the hazardous area would cause the INLET VALVES TO BE FULLY OPEN
risk of an explosion. WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
This sign is not a safety symbol but recommended minimum flow continuously will cause
indicates an important instruction in the assembly damage to the pump itself and to the seal.
process.
DO NOT RUN THE PUMP AT
1.6.2 Personnel qualification and training ABNORMALLY HIGH OR LOW FLOW RATES
All personnel involved in the operation, installation, Operating at a flow rate higher than normal or at a
inspection and maintenance of the unit must be flow rate with no back pressure on the pump may
qualified to carry out the work involved. If the overload the motor and cause cavitation. Low flow
personnel in question do not already possess the rates may cause a reduction in pump/bearing life,
necessary knowledge and skill, appropriate training overheating of the pump, instability and cavitation/
and instruction must be provided. If required the vibration.
operator may commission the manufacturer / supplier
to provide applicable training. NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

immediate area. Note: bearing housings must not be


insulated and drive motors and bearings may be hot.
HAZARDOUS LIQUIDS
If the temperature is greater than 68 C (175 F) or
When the pump is handling hazardous liquids care
below 5 C (20 F) in a restricted zone, or exceeds
must be taken to avoid exposure to the liquid by
local regulations, action as above shall be taken.
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
1.6.4 Products used in potentially explosive
flammable and/or explosive, strict safety procedures
atmospheres
must be applied.
Measures are required to:
Gland packing must not be used when pumping
Avoid excess temperature
hazardous liquids.
Prevent build up of explosive mixtures
DRAIN THE PUMP AND ISOLATE PIPEWORK Prevent the generation of sparks
BEFORE DISMANTLING THE PUMP Prevent leakages
The appropriate safety precautions should be taken Maintain the pump to avoid hazard
where the pumped liquids are hazardous.
The following instructions for pumps and pump units
FLUORO-ELASTOMERS (When fitted.) when installed in potentially explosive atmospheres
When a pump has experienced temperatures over must be followed to help ensure explosion protection.
250 C (482 F), partial decomposition of fluoro- Both electrical and non-electrical equipment must
elastomers (eg Viton) will occur. In this condition meet the requirements of European Directive
these are extremely dangerous and skin contact must 94/9/EC.
be avoided.
1.6.4.1 Scope of compliance
HANDLING COMPONENTS
Many precision parts have sharp corners and the Use equipment only in the zone for which it is
wearing of appropriate safety gloves and equipment appropriate. Always check that the driver, drive
is required when handling these components. To lift coupling assembly, seal and pump equipment are
heavy pieces above 25 kg (55 lb) use a crane suitably rated and/or certified for the classification of
appropriate for the mass and in accordance with the specific atmosphere in which they are to be
current local regulations. installed.

GUARDS MUST NOT BE REMOVED WHILE Where Flowserve has supplied only the bare shaft
THE PUMP IS OPERATIONAL pump, the Ex rating applies only to the pump. The
The unit must not be operated unless coupling guard party responsible for assembling the pump set shall
is in place. Failure to observe this warning could select the coupling, driver and any additional
result in injury to operating personnel. equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
THERMAL SHOCK the area in which it is to be installed.
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result The output from a variable frequency drive (VFD) can
in damage or breakage of components and should be cause additional heating affects in the motor and so,
avoided. for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
NEVER APPLY HEAT TO REMOVE IMPELLER where electrical supply is from the VFD. This
Trapped lubricant or vapour could cause an particular requirement still applies even if the VFD is
explosion. in a safe area.

HOT (and cold) PARTS


If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

1.6.4.2 Marking
An example of ATEX equipment marking is shown The responsibility for compliance with the
below. The actual classification of the pump will be specified maximum liquid temperature is with the
engraved on the nameplate. plant operator.

II 2 GD c IIC 135 C (T4) Temperature classification Tx is used when the


liquid temperature varies and when the pump is
Equipment Group required to be used in differently classified potentially
I = Mining explosive atmospheres. In this case the user is
II = Non-mining responsible for ensuring that the pump surface
temperature does not exceed that permitted in its
Category
actual installed location.
2 or M2 = high level protection
3 = normal level of protection
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
Gas and/or dust
rotation by starting the pump unfilled. Even a short
G = Gas
run time may give a high temperature resulting from
D = Dust
contact between rotating and stationary components.
c = Constructional safety
(in accordance with prEn13463-5) Where there is any risk of the pump being run against
a closed valve generating high liquid and casing
Gas Group (Equipment Category 2 only) external surface temperatures it is recommended that
IIA Propane (typical) users fit an external surface temperature protection
IIB Ethylene (typical) device.
IIC Hydrogen (typical)
Avoid mechanical, hydraulic or electrical overload by
Maximum surface temperature (Temperature Class) using motor overload trips, temperature monitor or a
(see section 1.6.4.3) power monitor and make routine vibration monitoring
checks.
1.6.4.3 Avoiding excessive surface temperatures
In dirty or dusty environments, regular checks must
ENSURE THE EQUIPMENT TEMPERATURE be made and dirt removed from areas around close
CLASS IS SUITABLE FOR THE HAZARD ZONE clearances, bearing housings and motors.
Pumps have a temperature class as stated in the 1.6.4.4 Preventing the build up of explosive
ATEX Ex rating on the nameplate. These are based mixtures
on a maximum ambient of 40 C (104 F); refer to
Flowserve for higher ambient temperatures. ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The Ensure the pump and relevant suction and discharge
maximum permissible liquid temperature depends on pipeline system is totally filled with liquid at all times
the temperature class and must not exceed the during the pump operation, so that an explosive
values in the table that follows. atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
The temperature rise at the seals and bearings and systems and any heating and cooling systems are
due to the minimum permitted flow rate is taken into properly filled.
account in the temperatures stated.
Maximum Temperature limit of liquid
If the operation of the system cannot avoid this
Temperature condition the fitting of an appropriate dry run
surface handled (* depending on
class to
EN 13463-1 temperature material and construction protection device is recommended (eg liquid
permitted variant - check which is lower) detection or a power monitor).
T6 85 C (185 F) Consult Flowserve
T5 100 C (212 F) Consult Flowserve To avoid potential hazards from fugitive emissions of
T4 135 C (275 F) 115 C (239 F) *
vapour or gas to atmosphere the surrounding area
T3 200 C (392 F) 180 C (356 F) *
T2 300 C (572 F) 275 C (527 F) *
must be well ventilated.
T1 450 C (842 F) 400 C (752 F) *

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

1.6.4.5 Preventing sparks adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
To prevent a potential hazard from mechanical must be conducted in a safe area.
contact, the coupling guard must be non-sparking
and anti-static for Category 2. It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the 1.7 Nameplate and safety labels
baseplate must be used.
1.7.1 Nameplate
Avoid electrostatic charge: do not rub non- For details of nameplate, see the Declaration of
metallic surfaces with a dry cloth; ensure cloth is Conformity.
damp.
1.7.2 Warning labels
The coupling must be selected to comply with
2006/42/EC and correct alignment must be
maintained.

1.6.4.6 Preventing leakage

The pump must only be used to handle liquids


for which it has been approved to have the correct
corrosion resistance.

Avoid entrapment of liquid in the pump and


associated piping due to closing of suction and
discharge valves, which could cause dangerous
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
running.

Bursting of liquid containing parts due to freezing


must be avoided by draining or protecting the pump
and ancillary systems.

Where there is the potential hazard of a loss of a seal


barrier fluid or external flush, the fluid must be
monitored.

If leakage of liquid to atmosphere can result in a


hazard, the installation of a liquid detection device is
recommended.

1.6.4.7 Maintenance to avoid the hazard

CORRECT MAINTENANCE IS REQUIRED TO


AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION

The responsibility for compliance with


maintenance instructions is with the plant
operator.
1.8 Specific machine performance
To avoid potential explosion hazards during For performance parameters see section 1.5, Duty
maintenance, the tools, cleaning and painting conditions. Pump performance data are summarised
materials used must not give rise to sparking or

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

on pump data sheet which is included in proper


section of Job Users Instruction. The dBA values are based on the noisiest ungeared
electric motors that are likely to be encountered.
1.9 Noise level They are Sound Pressure levels at 1 m (3.3 ft) from
When pump noise level exceeds 85 dBA attention the directly driven pump, for "free field over a
must be given to prevailing Health and Safety reflecting plane".
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to If a pump unit only has been purchased, for fitting
control exposure time to the noise or to enclose the with your own driver, then the "pump only" noise
machine to reduce emitted sound. You may have levels should be combined with the level for the driver
already specified a limiting noise level when the obtained from the supplier. If the motor is driven by
equipment was ordered, however if no noise an inverter, it may show an increase in noise level at
requirements were defined then machines above a some speeds. Consult a Noise Specialist for the
certain power level will exceed 85 dBA. In such combined calculation.
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.

Pump noise level is dependent on a number of


For units driven by equipment other than
electric motors or units contained within enclosures,
factors - the type of motor fitted, the operating see the accompanying information sheets and
conditions, pipework design and acoustic manuals.
characteristics of the building. The levels specified in
the table 1.1 are estimated and not guaranteed.

Typical sound pressure level, dBA, LpA at 1 m reference 20 Pa (LwA sound power 1pW where LpA >85 dBA)
B B B B B B

Motor size 3500 rpm 2900 rpm 1750 rpm 1450 rpm
and speed Pump Pump & Pump Pump & Pump Pump & Pump Pump &
only motor only motor only motor only motor
kW (hp) dBA dBA dBA dBA dBA dBA dBA dBA
<0.55 (<0.75) 72 72 64 65 62 64 62 64
0.75 (1) 72 72 64 66 62 64 62 64
1.1 (1.5) 74 74 66 67 64 64 62 63
1.5 (2) 74 74 66 71 64 64 62 63
2.2 (3) 75 76 68 72 65 66 63 64
3 (4) 75 76 70 73 65 66 63 64
4 (5) 75 76 71 73 65 66 63 64
5.5 (7.5) 76 77 72 75 66 67 64 65
7.5 (10) 76 77 72 75 66 67 64 65
11 (15) 80 81 76 78 70 71 68 69
15 (20) 80 81 76 78 70 71 68 69
18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78
110 (150) 89 90 85 87 79 80 77 80
132 (175) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80
160 (215) (1) (1) (1) (1) 83 84 81 83
200 (270) (1) (1) (1) (1) 85 87 83 85
300 (400) 87 90 85 86
315 (422) 87 90 85 86
355 (475) 87 90 86 87
500 (670) 88 (1) 86 (1)
1000 (1300) 90 (1) 88 (1)
1500 (2000) 90 (1) 90 (1)
(1) Noise levels of machines in this range should be based on actual equipment selected
For 1180 and 960 r/min reduce the 1450 r/min values by 2dBA

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

For 880 and 720 r/min reduce the 1450 r/min values by 3dBA

2 TRANSPORT AND STORAGE half couplings before lifting baseplate with


pumping element.
2.1 Consignment receipt and unpacking To lift pump and baseplate, less driver, or
Immediately after receipt of the equipment it must be baseplate alone, sling from all four (4) eye bolts.
checked against the delivery and shipping documents
for its completeness and that there has been no
damage in transportation.

Any shortage and or damage must be reported


immediately to Flowserve and received in writing
within one month of receipt of the equipment. Later
claims cannot be accepted.

Check any crates, boxes and wrappings for any


accessories or spare parts which may be packed
separately with the equipment or attached to side
walls of the box or equipment.

Each product has a unique serial number. Check that


this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories. Figure 2.1

2.2 Handling Do not lift pump, motor, baseplate


Boxes, crates, pallets or cartons may be unloaded unit by slinging from pump casing and/or eye bolt
using fork-lift vehicles or slings dependent on their on motor.
size and construction.
2.3.2 To lift driver
2.3 Lifting Refer to Manufacturers Instructions.

2.3.3 To lift complete pump only


Rig lifting straps at coupling end of bearing housing
Make sure that any equipment used to lift the pump and at suction nozzle. Make sure straps are adjusted
or any of its components is capable of supporting the to obtain an even lift.
weights encountered. Make sure that all parts are
correctly rigged before attempting to lift.

A crane must be used for all pump sets in


excess of 25 kg (55 lb). Fully trained personnel must
carry out lifting, in accordance with local regulations.
The driver and pump weights are recorded on
general arrangement drawing included into the job
users instruction.

2.3.1 To Lift unit


Figure 2.2
Pump, driver and baseplate can be lifted as a unit.
Sling from all four (4) eye bolts provided on baseplate 2.4 Storage
side rails. Failure to use all four (4) could result in
permanent distortion of the baseplate. Use as long a Store the pump in a clean, dry location
sling as possible, or use a spreader arrangement. away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
pump casing. Turn pump at intervals to prevent
Coupling bolting and spacer piece brinelling of the bearings and the seal faces, if fitted,
must be removed from between pump and driver from sticking.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Electric Motors (Pump Driver) should not be stored in be protected from dirt, dust, rain, snow, or other
damp places without special protection (Refer to unfavourable conditions by heavy plastic sheets,
Motor manufacturers instructions). canvas, waterproof burlap or other suitable coverings.
All equipment must be placed upon skids or blocks to
The pump may be stored as above for up to 6 prevent contact with the ground and surface
months. contaminants. Equipment must be adequately
supported to prevent distortion and bending.
2.4.1 Long term storage The pump shaft should be rotated, in the direction of
During extended periods of storage prior to rotation, at least 1 and 1/4 turns each week during
installation, precautions must be taken to protect the the storage period and any other periods of stand by.
pump from deterioration. The various parts of the When selecting a storage area the following should
pump are protected prior to shipment by applying be taken into consideration.
varying grades of preservative to the parts. However,
during shipment and handling the preservatives are a) The deterioration of the equipment will be
subjected to conditions that can cause their removal. proportionate to the class of storage provided.
Also, during extended periods of time the b) The expenses involved in restoring the
preservatives may deteriorate. The listed procedures equipment at time of installation will be
(2.4.1.1 to 2.4.1.5) should be followed to prevent proportionate to the class of storage provided.
deterioration of the pump during the extended
storage period. These procedures may also be 2.4.1.3 Inspection and maintenance
supplemented by the experience of the person(s) The stored equipment has to be placed on a periodic
performing the tasks. inspection schedule by the purchaser.
The responsibility for setting up an inspection
2.4.1.1 Inspection upon arrival schedule rests with the purchaser and will be
When the pump is received it should be inspected for dependent upon the class of storage provided. It
damage or other signs of rough handling. If any would be expected initially, inspection would occur
damage is found it should be reported to the carrier weekly, then depending upon the inspection reports
immediately. Inspect the preservative coating on being favourable or unfavourable, inspection would
various parts. If necessary, renew preservative in continue weekly, monthly, or quarterly, as may be
areas where it has been rubbed or scraped. determined.
Inspect all painted surfaces. If necessary, touch up Each inspection should consist of a general surface
the areas where paint has been chipped or scraped. inspection to assure that:
Inspect all covers over pump openings and piping
connections. If covers or seals for the covers are a) Pump supports are firmly in place.
damaged or loose, they are to be removed, and a b) Pump covers over openings are firmly in place.
visual inspection made of the accessible interior c) Pump coverings, plastic or tarps are firmly in
areas for accumulation of foreign materials or water. place. Any holes or tears must be repaired to
If necessary, clean and preserve the interior parts as prevent entrance of dirt or water.
noted above to restore the parts to the "as shipped" d) Pump covers are periodically removed from
condition. Install or replace covers and fasten openings and interior accessible areas inspected.
securely. If surface rusting has occurred, clean or coat with
preservative.
2.4.1.2 Storage e) If rusting occurs on exterior surfaces clean and
repaint or coat with preservative.
If at all possible, the pump and its f) Check individually wrapped parts for signs of
component parts should be stored indoors where deterioration. If necessary, renew preservative
they will be protected from the elements. In no case and wrapping.
should any pump element be subjected to extended
periods of submergence or wetting prior to start up. If Six months prior to the scheduled installation date, a
it is not possible to store the pump and its FLOWSERVE representative is to be employed to
components indoors, precautions must be taken to conduct an inspection. This inspection may include,
protect them from the elements. Regardless of not necessarily in its entirety and not limited to the
whether storage is indoors or outside, the storage following:
area should be vibration free. All boxes marked for
indoor storage should be stored indoors. When a) An inspection of all periodic inspection records as
stored outdoors the pump and its components should kept on file by the purchaser, and all inspection

Page 11 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

reports that have been compiled during the Generally rotors of associated equipment should be
storage period. blocked to relieve bearing loads. Storage should be
b) An inspection of the storage area to determine indoors and dry. See the specific manufacturers
the "as stored" condition of the equipment prior to storage requirements.
any protection covers being removed.
c) An inspection of the equipment with protective 2.5 Recycling and end of product life
covers and flange covers removed. At the end of the service life of the product or its
d) Depending upon the length of time the equipment parts, the relevant materials and parts should be
was stored, the type of storage provided (i.e. recycled or disposed of using an environmentally
Indoor: heated, unheated, ground floor, concrete acceptable method and local regulations. If the
floor. Outdoors: under roof, no roof, waterproof product contains substances which are harmful to the
coverings, on concrete, on ground) and as a environment, these should be removed and disposed
result of the inspection of (a),(b) & (c) above the of in accordance with current regulations. This also
FLOWSERVE representative may require a includes the liquids and or gases in the "seal system"
partial or complete dismantling of the equipment. or other utilities.
e) Dismantling may necessitate restoration of
painted or preserved surfaces, and, or
replacement of gaskets, "O" rings, packing and Make sure that hazardous substances or
bearings. toxic fluids are disposed of safely and that the correct
f) All costs involved during inspection, dismantling, personal protective equipment is used. The safety
restoration, replacement of parts and reassembly specifications must be in accordance with the current
will have to the accounted to the purchaser. All regulations at all times.
necessary labour, tools and cranes will be 3 PUMP DESCRIPTION
supplied by the purchaser.
3.1 Configurations
Upon completion of the inspection the FLOWSERVE The type HPX-H; HPX-MP pump is a single stage,
representative shall submit a report to the purchaser, horizontal, end suction process pump with overhung
and to the Manager of Customer Service, stating in impeller and radially split casing, fully compliant to
detail the results of the inspection. API 610/682 The range is designed for continuous
One month prior to installation of the equipment, a service in all process applications including oil
FLOWSERVE representative is to be employed to exploration and production, oil refining,
conduct a final inspection. This inspection will be petrochemical, chemical and general industrial
made to assure that the requirements of the six usage.
months inspection report were satisfactorily
completed and that the equipment is ready for 3.2 Nomenclature
installation. The pump size will be engraved on the nameplate
Upon completion of this inspection the FLOWSERVE typically as below:
representative shall submit a final report to the 6-HPXH-12-A
purchaser, and to the Manager of Customer Service,
advising the results of the final inspection. Nominal discharge branch size
All costs involved in conducting the final inspection
will have to the accounted to the purchaser. Pump type
Prior to and during start up, any requirements for the
services of an FLOWSERVE representative will Nominal full size impeller diameter
revert back to the original contract agreement for
equipment purchased, with revised costing. Casing pattern type
2.4.1.4 Painting and preservation The typical nomenclature above is the general guide
Paints and preservatives used are either to the HPXH, HPX-MP description. Identify the actual
FLOWSERVE standard or 'special' as required by the pump size and serial number from the pump
contract specification. Refer to FLOWSERVE for the nameplate. Check that this agrees with the
description of paints and preservatives used on this applicable certification provided.
order if needed
2.4.1.5 Associated equipment
Motors, Turbines, Gears, etc., being supplied by
FLOWSERVE.

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3.3 Design of major parts


3.3.6 Bearing housing
3.3.1 Pump casing The bearing housing is fitted with an end cover on the
The casing is centre line supported with end suction outboard end for ease of inspection and
and top discharge. It provides for the immediate maintenance. Each end of the housing is fitted with a
containment of liquid being pumped as the liquid is standard labyrinth type shaft seal (made from non-
directed from the suction nozzle through the impeller sparking materials) to effectively retain the oil and
and then through the volute to the discharge nozzle. prevent entry of any foreign matter. Special
The casing has mounting feet integrally cast on the outsourced baring isolators are available as an
centerline of the pump thus giving a rigid construction option. The standard bearing lubrication is provided
and preventing distortion in high temperature by a shaft mounted metal slinger that transfers oil to
applications. A wear ring is mounted in the casing to bearing feed galleries within the housing wall.
provide a close running clearance with the impeller
wear ring. Ring oil lubrication is optional. Two metal slingers are
positively locked on the shaft with set screws and
3.3.2 Impeller bearing lubrication is provided by a heavy duty oil
The impeller is a single suction, radial flow, closed ring. A plugged port on the top of the bearing housing
design. The impeller is dynamically balanced, keyed is positioned to allow visual inspection of the oil ring.
to the shaft and secured by locknut and lockscrew. Oil mist lubrication is optional; Purge oil mist
Renewable wear rings are press fit onto the impeller provisions are available on either slinger or ring oil
hubs (front and back once applicable) and positively designs. Pure oil mist (no slinger, no oil ring) is also
secured with axial screws or tack welding. available. TRICO constant level oiler is supplied as
standard. For purge oil mist, a balanced type oiler is
3.3.3 Inducer and/or Coke Crusher used. No oiler is supplied for pure oil mist. When
Inducers are available on most pump models for low application requires, the standard cooling system is a
NPSH conditions. The inducer replaces the standard fan, either with slinger or oil ring lubrication. Optional
impeller locknut and lockscrew. It is secured by water cooling is available, should this be a customer
proper cap nut and security washer. preference.
Coke Crusher are provided on suction impeller to
break up coke particles when produced in refining or 3.3.7 Pump bearings and lubrication
petrochemical processes. If those particles are too Heavy duty, single row radial bearing and duplex
large, they are trapped between impeller vanes and taper roller thrust bearings arranged face to face
reduce or stall the flow. Coke Crusher prevents coke ensure long life under the most severe operating
particles that are too large to travel between impeller conditions. The bearings are a sliding fit in the
vanes. Rotation carries particles around stator bearing housing and a light interference fit on the
barrage lugs where the particles are crushed. shaft in accordance with AFBMA recommendations.
Lubrication of the bearings is provided by oil rings,
3.3.4 Casing cover thrower, purge mist or pure mist as a customer
The casing cover is either fabricated from plate or option.
cast, depending on the material of construction.
Designed to the dimensional standards within the API 3.3.8 Shaft seal
682 specification 'Table 1', the seal chamber can The mechanical seal(s), attached to the pump shaft,
accommodate a wide variety of single or dual seal seals the pumped liquid from the environment. Gland
arrangements as standard. packing may be fitted as an option.

3.3.5 Shaft 3.3.9 Driver


The shaft is of ample strength and rigidity. It is The driver is normally an electric motor. Different
precision machined over its entire length and has drive configurations may be fitted such as internal
generous fillet radii at each change of section to combustion engines, turbines, hydraulic motors etc
reduce stress concentrations. Shaft deflections at the driving via couplings, belts, gearboxes etc.
seal chamber are minimal and fall within the
guidelines stated in API 610. 3.3.10 Coupling/Coupling guards
An optional extra heavy duty shaft design, with very Flexible spacer couplings are provided in various
low l3/d4 values, is available on most centerline makes and models to suit customer preference.
discharge pump sizes. (Aluminium non- hinged guards are provided)

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

3.3.11 Baseplate allow it to be pumped easily. Liquid may have to


Standard baseplates are welded steel, drain pan type be heated prior to pump start-up.
in conformance with API 610 standardised
dimensions. Horizontal driver alignment screws and 3.4.3 Changing the pump speed
vertical baseplate levelling screws are provided when Changing pump speed effects flow, total head, power
required by API. absorbed, NPSHR, noise and vibration. Flow varies
Special baseplates can be supplied to suit individual in direct proportion to pump speed. Head varies as
installation circumstances. speed ratio squared. Power varies as speed ratio
cubed. If increasing speed it is important therefore to
3.3.12 Accessories ensure the maximum pump working pressure is not
Accessories may be fitted when specified by the exceeded, the driver is not overloaded,
customer. NPSHA>NPSHR, and that noise and vibration are
Baseplates are fabricated and machined so to within local requirements and regulations.
guarantee the flatness and parallelism of pads as
required by API standard. The requirement is met by 3.4.4 Net Positive Suction Head (NPSH)
supporting and clamping the baseplate at the Any liquid, hot or cold, must be pushed into the
foundation bolt holes only. impeller of the pump by absolute pressure, such as
the atmospheric or vessel pressure from which the
3.4 Performance and operating limits pump takes its suction.
This product has been selected to meet the The head in feet of liquid necessary to push the
specifications of your purchase order see section 1.5. required flow into the pump is called Net Positive
Suction Head. This value, more commonly called
These pumps are furnished for a particular service NPSH, is measured above the vapour pressure of the
condition. Changes in the hydraulic system may liquid at the pumping temperature.
affect the pump's performance adversely. This is There are two kinds of NPSH: the NPSHR is the head
especially true if the changes reduce the pressure at required by the pump to cover the losses in the pump
the suction flange or if the liquid temperature is suction - that is shown on the pump characteristic
increased. In case of doubt, contact the nearest curve. The second, NPSHA, is the head available in
FLOWSERVE office. the system, taking into account friction loss in suction
piping, valves, fittings etc. In all cases the NPSHA,
3.4.1 Effect of specific gravity measured above vapour pressure, must exceed the
Pump capacity and total head in metres (feet) do not NPSHR in order to push the liquid into the pump.
change with SG, however pressure displayed on a Failure to have this will result in both bad
pressure gauge is directly proportional to SG. Power performance and mechanical damage to the pump,
absorbed is also directly proportional to SG. and in certain cases actual pump failure.
It is therefore important to check that any change in If any change in NPSHA is proposed, ensure its
SG will not overload the pump driver or over- margin over NPSHR is not significantly eroded. Refer
pressurise the pump. to the pump performance curve to determine exact
requirements particularly if flow has changed. If in
3.4.2 Effects of viscosity doubt please consult your nearest Flowserve office
The pump is designed to deliver rated capacity and for advice and details of the minimum allowable
rated head for a liquid with a particular viscosity. margin for your application.
For a given flow rate the total head reduces with
increased viscosity and increases with reduced 3.4.5 Minimum Continuous Stable Flow
viscosity. Also for a given flow rate the power The Minimum Continuous Stable Flow for the pump is
absorbed increases with increased viscosity, and stated on the Data sheet.
reduces with reduced viscosity.
When contemplating operation at some viscosity 3.4.6 Minimum flow control
other than the one for which the pump was originally In all cases, it is the customer's responsibility to
designed and/or applied, the changed conditions supply a system and/or control which assures that
should be referred to FLOWSERVE for any pump within a system is not operated below its
recommendations. minimum flow condition.
In many cases, this is not a problem because the
system is operating within its own flow range to
When pump is handling heavy assure product delivery. A simple high pressure
viscous liquid, the temperature of the liquid must alarm, shut down and/or bypass control can be used.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

However, in systems where product demand has high


swings or where more than 100% capacity units are Prior to grouting, an initial alignment
desired to support a product system, additional care check in accordance with the alignment section of
must be taken. this document shall be performed to verify that
coupling spacing and final alignment can be achieved
3.4.7 Thermal control without modifying the hold down bolts or the machine
A thermal control of the unit can be provided by feet. This is necessary to ensure that the baseplate
thermal sensors which read direct or "related to" fluid was not damaged during the transportation.
temperatures and respond accordingly by opening
additional flow paths until the given unit re- 4.3 Foundation
establishes the acceptable temperature rise, and sets
off alarms if not achieved within reasonable/normal There are many methods of installing
time periods. (High limit could actually shut down pump units to their foundations. The correct method
unit). depends on the size of the pump unit, its location and
noise vibration limitations. Non-compliance with the
3.4.8 Pressure and/or Flow Control provision of correct foundation and installation may
Pressure and/or flow sensors can be used to hold the lead to failure of the pump and, as such, would be
unit at higher flows by opening additional flow paths outside the terms of the warranty.
once a "high pressure limit" or " low flow limit" was The foundation should be sufficiently rigid and
indicated. Upon system reaching increased flow a substantial to prevent any pump vibration and to
"low pressure limit" or "high flow limit" setting would permanently support the baseplate at all points.
close the bypass flow path. Care must be taken to The most satisfactory foundations are made of
allow for signal spread to avoid cyclic conditions. reinforced concrete. These should be poured well in
advance of the installation to allow sufficient time for
3.4.9 Operating at Reduced Capacity drying and curing.
The General Arrangement Drawing (In Jobs User
Damage to pump may result from Instruction) will furnish overall outline of pump
prolonged operations at capacities less than MCSF baseplate, anchor bolt locations, size of bolts, etc in
as stated in Data Sheet. order to provide proper shape to the primary
concrete. Anchor bolts can be positioned or by a
4 INSTALLATION special template (not supplied by FLOWSERVE see
figure 4.1) or by the baseplate itself if proper pockets
have been provided in primary concrete.
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.

4.1 Location
Install the unit close to the source of the liquid to be
pumped.
It is desired to have a straight length of suction pipe
(approx. 7 to 10 times the pipe diameter) just
upstream of suction nozzle (No double turns).
When selecting the location, be sure to allow
adequate space for operation as well as for
maintenance operations involving dismantling and
inspections of parts.
Head room is an important consideration as an
Figure 4.1
overhead lift of some type is required. Template for Hanging Foundation Bolts

4.2 Part assemblies Figure 4.2 below illustrates an alternative foundation


Motors may be supplied loose. It is the responsibility bolt arrangement which can be used in lieu of
of the installer to ensure that the motor is assembled standard foundation bolts. Notice the large washer
to the pump and lined up as detailed in section 4.5.2. with lugs at the bottom. It should be welded to the
bolt and pipe sleeve to prevent turning.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Allow a little more than the specified threaded bolt


length above the rail of the baseplate. The excess
can always be cut off if it is not needed. When lifting baseplate with pumping
A rough finish top surface is best when applying element, sling baseplate from all lifting lugs provided.
grout. Refer to Section 2.3.1

ALLOW AMPLE THREADED


BOLT LENGTH ABOVE
Prepare sufficient steel plates to be placed below
ROUGH CONCRETE
each baseplate jacking screw furnished with the
ROUGH FINISH
FOR GROUT baseplate. The purpose of the plate is to spread the
STUFF WASTE AROUND
BOLT WHILE POURING
load of the screw without crushing the concrete
CONCRETE
below.

PIPE SLEEVE TO BE
THREE TIMES DIAMETER
OF ANCHOR BOLT

WELD A LARGE WASHER


WITH LUGS TO THE
BOTTOM OF BOLT
AND PIPE SLEEVE TO
PREVENT TURNING

Figure 4.2

4.3.1 Baseplate levelling Not supplied


Before putting the unit on the foundation, thoroughly
Figure 4.3
clean the top of the foundation. Break off any loose
pieces of cement and roughen the top with a chisel to 4.3.2 Method of levelling baseplate using wedges
afford a good hold for grout. or shims
In case of installation over a steel structure (platform) a) Level the baseplate by using a machinist's level
ensure that the top of the steel structure is cleaned on the machined surfaces of the pump and driver
and degreased. pads. Levelling is best achieved by adjusting the
shim pack thickness under each holding bolt.
Carefully raise the baseplate by using either the
In order to obtain the parallelism and baseplate jacking screws provided or by levering
flatness of pads required by API standard, baseplate with a suitable pinch bar or by installing a low
has to be properly levelled by levelling screws level hydraulic jack.
provided on it and clamping the baseplate at the b) Adjust the shim pack thickness and lower the
foundation bolts only (For proper detailed procedure baseplate.
refer to Chapter 5 para 3.9.4 of API RP 686 ). c) Repeat this procedure in a logical manner at
each bolt position until the baseplate is both
straight and levelled. A degree of 0.25 mm per
Coupling bolting and spacer piece must metre (0.0035 inch per foot) length is achievable
be removed from between the pump and driver half on most units with a maximum of 0.40 mm per
couplings before lifting baseplate with pumping metre length (0.005 inch per foot).
element d) In case of installation on steel structures (like
platforms) proceed with these extra steps:
Using a calibrated pin with a cone point mark
When the unit is mounted directly on the centre of baseplate support pads
structural steel framing, it should be located directly mounting holes on the soleplate.
over as near as possible to the main building
Lift and move away the pump skid.
members, beams, or walls. A soleplate should be
Drill and tap the soleplate fixing holes.
bolted or welded to the steel frame to guarantee the
proper surface.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Replace the pump skid so that the soleplate


fixing holes align with the baseplate support Do not vibrate baseplate when grouting,
pads mounting holes. making sure baseplate is vented correctly and all
Level the unit like done previously (see points areas are thoroughly puddle to prevent any resonant
a, b, c). problems.
e) When the baseplate is level, pull down the When the grout is thoroughly hardened, remove the
foundation bolts so they are snug or tighten the dam and wedges, if desired, filling in the holes they
fixing bolts in case of installation on steel leave with grout.
structure. This may have disturbed the baseplate,
so re-check the levels.
f) Ensure that shaft alignment per Section 4.5 can Pour grout until level reaches top of dam.
be achieved prior to grouting the baseplate. Allow to dry sufficiently to prevent grout from
overflowing while completing the remaining grouting.
4.4 Grouting
Build a dam around the foundation as shown in 4.4.2 Baseplate not Intended for Grouting but
Figure 4.4 after levelling the baseplate. It is a matter Installed on Concrete Foundations
of personal preference whether the levelling wedges
under the baseplate should be removed after According to the figure 4.5 and 4.6 the baseplate will
grouting. If you do not want to remove the wedges, not be grouted but only a sealing shall be provided.
carefully mark their locations before pouring grout. During the preparation, as indicated on the General
Arrangement drawing a certain number of openings
into the sealing must be guaranteed. After the sealing
the blocks used to realise the openings must be
Before grouting, level machined
removed. Blocks have to be wider than the baseplate
pads of baseplate in both directions and perform
longitudinal beam in order to guarantee the opening
a rough shaft/coupling alignment. Alignment after
for the drainage.
grout has set will not be possible if above is not
satisfactorily completed.

4.4.1 Fully Grouted Baseplates

FINISHED GROUT

LEAVE TOP OF
FOUNDATION ROUGH
DO NOT FINISH
WITH TROWEL

DAM GROUTING 1 TO 2
INCHES DEEP Not supplied
BLOCK TO BE REMOVED
CONCRETE
AFTER THE SEALING
Figure 4.4

Figure 4.5
Use a good, high strength, non shrink grout mix and
install as per manufacturer's instructions.
Holes are provided in the baseplate to permit pouring
the grout and stirring while acting as air vents. Fill
under the baseplate completely, stirring to assure
correct distribution of the grout. Check to see that the
grout flows under the edges of the baseplate evenly.

Page 17 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

baseplate/foundation deflection and vibration during


operation may require the full coupling misalignment
capability.

4.5.2.1.1 Types of misalignment


There are two types of shaft misalignment: angular
SEALING and offset. Therefore, two sets of measurements and
corrections are required. Both types of misalignment
can occur in horizontal and vertical planes and are
present in most applications.

PRIMARY A) Angular misalignment


TOP OF FOUNDATION CONCRETE In angular misalignment, the centre line of the shafts
intersect, but are not on the same axis.
Figure 4.6

4.5 Initial alignment


4.5.1 Thermal expansion

The pump and motor will normally


have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion at
operating temperature.
Figure 4.7

4.5.2 Alignment methods B) Offset misalignment


In offset misalignment, the shaft centre lines are
Ensure pump and driver are isolated
parallel but do not intersect.
electrically and the half couplings are disconnected.

The alignment MUST be checked.


Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
Figure 4.8 offset misalignment
4.5.2.1 Shaft/Coupling alignment

Shaft alignment must be correct for


successful operation. Rapid wear, noise, vibration
and actual damage to the equipment may be
caused by shaft misalignment. The shafts must
be aligned within the limits given within this
section.

Figure 4.9 combination of offset and angular misalignment


Adjustment to correct the alignment in one
direction may alter the alignment in another direction.
Always check in all directions after making any 4.5.2.2 Alignment using the reverse dial Indicator
adjustment. The following practices are recommended when
Coupled equipment must be aligned to minimise using the reverse method of alignment. These should
unnecessary stresses in shafts, bearings and be carried out prior to main alignment.
coupling. Flexible couplings will not compensate for
appreciable misalignment. Foundation settling,
thermal expansion or nozzle loads resulting in

Page 18 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

For detailed alignment procedure refer to API RP686.

Figure 4.10

CHECK FOR SOFT FOOT

This is a check to ensure that there is no undue


stress on the driver holding down bolts; owing to non-
level baseplate or twisting. To check, remove all
Figure 4.11
shims and clean surfaces and tighten down driver to
the baseplate. Set a dial indicator as shown in sketch Maximum permissible misalignment at working
and loosen off the holding down bolt while noting any temperature:
deflection reading on the Dial Test Indicator - a Parallel 0.05 mm (0.002 in.) TIR
maximum of 0.05 mm (0.002 in.) is considered Angular 0.05mm/100mm (0.0005In/In)
acceptable but any more will have to be corrected by
adding shims, for example, if the Dial Test Indicator Pumps with thick flanged non-spacer couplings can
shows the foot lifting 0.15 mm (0.006 in.) then this is be aligned by using a straight-edge across the
the thickness of shim to be placed under that foot. outside diameters of the coupling hubs and
Tighten down and repeat the same procedure on all measuring the gap between the machined faces
other feet until all are within tolerance using feeler gauges, measuring wedge or calipers.

When the electric motor has sleeve bearings it is


If the driver is an electric motor with sleeve necessary to ensure that the motor is aligned to run
bearings then the magnetic centre at which the rotor on its magnetic centreline.
will run must be set. This is usually done by lining up
a groove in the shaft to a pointer fixed to the motor
body (refer to Motor Manufactures instructions). Refer to the motor manual for details.
A button (screwed into one of the shaft ends) is
normally fitted between the motor and pump shaft
Ensure pump and driver are isolated ends to fix the axial position.
electrically and the half couplings are disconnected.
If the motor does not run in its
The alignment MUST be checked. magnetic centre the resultant additional axial force
Although the pump will have been aligned at the may overload the pump thrust bearing.
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If Complete piping as below and see sections 4.7,
necessary, align the motor to the pump, not the pump Final shaft alignment check up to and including
to the motor. section 5, Commissioning, start-up, operation and
The alignment is achieved by adding or removing shutdown before connecting driver and checking
shims under the motor feet and also moving the actual rotation.
motor horizontally as required. In some cases where
the alignment cannot be achieved it will be necessary 4.5.3 Shims
to move the pump before recommencing the above The shims between the equipment feet and mounting
procedure. surface should be clean and dry. This is especially
critical for pumps in service for sometime and need to
For couplings with narrow flanges use a dial indicator be realigned. Water, dirt and rust may change the
as shown on figure 4.11 to check both parallel and height of the shim pack over a period of time. Shims
angular alignment. should be made large enough to support the weight

Page 19 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

of the equipment on its mounting foot. Do not use


many thin shims as this may result in a spongy Before attempting any inspection or repair
mounting. on the pump the driver controls must be in the
"off" position, locked and tagged to prevent
restarting equipment and injury to personnel
performing service on the pump.
4.5.5 Assemble coupling
a) Assemble coupling as per the manufacturer's
instructions included in Appendix of this manual.
Figure 4.12 b) Install coupling guard
Recommended shim design
4.5.6 Installation check list
Move the equipment vertically by adding or removing a) Level Baseplate?
the calculated thickness of shims. Torque holding b) Grout Baseplate - Check Foundation Bolts?
down bolts to required values. c) Alignment Shaft/Coupling?
d) Piping Installed - Correct Vent, Gauge, Valve,
4.5.4 Hot alignment Pump and driver dowels Suction Strainer Locations?
Pump hold down bolts are to be torqued down and e) All Flange Bolting Correctly Torqued with
dowel pins are to be located in pump feet as Figure appropriate gaskets in place?
4.10. (This is only applicable if Hot Alignment is f) Check Shaft/Coupling Alignment again.
required) g) Coupling guard correctly installed?

4.6 Piping
Never use the pump as a support for
piping

4.6.1 General
These units are furnished for a particular service
condition. Changes in the hydraulic system may
affect performance adversely. This is especially true if
the changes reduce the pressure at the suction or if
the liquid temperature is increased. In case of doubt
contact FLOWSERVE
Suction and discharge piping should be of ample
size, be installed in direct runs, and have a minimum
of bends. Double bends must be avoided in suction
Figure 4.13 line and a straight run of pipe, equal 7 to 10 times the
Pump Dowel pin location pipe diameter is desired directly upstream of the
suction nozzle.
Refer to driver outline drawing and/or driver In order to minimise friction losses and hydraulic
instructions for driver doweling information. noise in the pipework it is good practice to choose
A hot check can only be made after the unit has been pipework that is one or two sizes larger than the
in operation a sufficient length of time to assume its pump suction and discharge. Typically main
NORMAL operating temperature and conditions. If pipework velocities should not exceed 2 m/s (6 ft/sec)
the unit has been correctly cold set, the offset suction and 3 m/s (9 ft/sec) on the discharge.
misalignment will be within the limits stated on par
4.5.2.2 when in operation.
If not make adjustments. Provision must be made to support piping
external to the pump to prevent excessive nozzle
Do not attempt any maintenance, loads, maintain pump/driver alignment and avoid pipe
inspection, repair or cleaning in the vicinity of induced vibrations.
rotating equipment. Such action could result in
injury to operating personnel. Take into account the available NPSH which must be
higher than the required NPSH of the pump.

Page 20 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Maximum forces and moments allowed on the pump


flanges vary with the pump size and type. To
minimize these forces and moments that may, if
excessive, cause misalignment, hot bearings, worn
couplings, vibration and the possible failure of the
pump casing, the following points should be strictly
followed:
Prevent excessive external pipe load
Never draw piping into place by applying force to
pump flange connections
Figure 4.14
Do not mount expansion joints so that their force, Cone Type Strainer
due to internal pressure, acts on the pump flange
The FLOWSERVE recommendation for suction
Ensure piping and fittings are flushed strainers consists of a conical shaped steel plate. The
before use. plate has 1.6 mm (1/16 in.) perforations and is of
sufficient size and thickness for the required flow.
Ensure piping for hazardous liquids is arranged See Figure above.
to allow pump flushing before removal of the pump.
Other type of strainers may be used as long as they
4.6.2 Suction piping conform to the requirements stated above.
a) The inlet pipe should be one or two sizes larger
than the pump inlet bore and pipe bends should Pressure gauges should be installed on both sides of
be as large radius as possible. the screen so that the pressure drop across the
b) Keep the suction pipe free of all air pockets. screen can be measured.
(Vent is required). When the unit is being started, the gauges on each
c) Pipework reducers should have a maximum total side of the screen should be carefully watched. An
angle of divergence of 15 degrees. increase in the differential pressure between the two
d) The piping should be inclined up towards the gauges indicates that the screen is becoming clogged
pump inlet with eccentric reducers incorporated with dirt and scale. At this point, the pump should be
to prevent air locks. shut down, and the screen cleaned and/or replaced.
e) Flow should enter the pump suction with uniform
flow, to minimise noise and wear.
f) Except if considerable foreign matter is expected A spool piece should be installed in
strainers are not recommended in inlet piping. suction line so that the suction strainer may be
Inlet strainers, when used, should have a net installed and removed with a pressure gauge
free area (see section 4.6.2.1) between the strainer and pump.

4.6.2.1 Suction strainer 4.6.2.2 Bypass Line


In a new installation, great care should be taken to
prevent dirt, scale, welding beads and other items
from entering the pump, as it is particularly important Operation at low flows results in
to protect the numerous close running fits from pump horsepower heating the liquid. A bypass
abrasive matter present in new piping may be required to prevent vaporisation and
subsequent pump damage. Refer to local
The suction system should be thoroughly flushed FLOWSERVE branch to determine if a bypass is
before installing the suction strainer and making up required. Mechanical damage may result from
suction piping to the pump. continuous operation at flows less than specified.
The suction strainer should be installed between 5 to
20 pipe diameters upstream from the pump suction 4.6.3 Discharge piping
flange. a) Install a check valve and a gate valve in the
discharge pipe of the pump. When the pump is
stopped, the check valve will protect the pump
The open area of the strainer should against excessive pressure and will prevent the
have a minimum of a 3 to 1 ratio to the area of the pump from running backward. The check valve
pump suction. should be installed between the gate valve and
the pump nozzle in order to permit its inspection.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Never throttle pump on suction side and never


place a valve directly on the pump inlet nozzle. It is important to be aware of the EUROPEAN
b) Pipework reducers should have a maximum total DIRECTIVE on potentially explosive areas where
angle of divergence of 15 degrees. compliance with IEC60079-14 is an additional
requirement for making electrical connections.
4.6.4 Drains
Pipe pump casing drains and gland leakage to a It is important to be aware of the EUROPEAN
convenient disposal point. DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
4.6.5 Pumps fitted with mechanical seals must be paid to ensure that the techniques used
Cartridge mechanical seals are provided, to seal the during wiring/installation do not increase
shaft against leakage. electromagnetic emissions or decrease the
The seals used on the "HPX-H; HPX-MP" pumps electromagnetic immunity of the equipment, wiring or
have internal design differences for sealing against any connected devices. If in any doubt contact
specific liquids and conditions. Flowserve for advice.

Long seal life with minimal leakage can only be The motor must be wired up in
obtained if the seals are provided with clean, cool accordance with the motor manufacturer's
liquid. Even tiny solids that may be suspended in the instructions (normally supplied within the terminal
liquid being pumped can damage the seal faces and box) including any temperature, earth leakage,
cause the seal to leak, making an external flush or a current and other protective devices as appropriate.
different seal arrangement necessary. The seal The identification nameplate should be checked to
balancing and flushing arrangement provided for ensure the power supply is appropriate.
each pump is designed and fitted for the specific
order requirements.
The "HPX-H; HPX-MP" pumps can be arranged with A device to provide emergency stopping must
either a single, dual mechanical pump seal. Refer to be fitted.
the General Arrangement for piping connections to be
used with your pump. If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be supplied
Mechanical seal replacement or servicing requires within the controller/starter.
that the pull out element be removed from the casing.
For removal of cartridge element refer to For electrical details on pump sets with controllers
Manufacturers instructions. see the separate wiring diagram.

See section 5.3, Direction of rotation


4.6.6 Final checks
before connecting the motor to the electrical supply.
Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of all
foundation bolts and auxiliary lines. 4.9 Protection systems
The following protection systems are
4.7 Final shaft alignment check recommended particularly if the pump is installed in a
After connecting piping to the pump, rotate the shaft potentially explosive area or is handling a hazardous
several times by hand to ensure there is no binding liquid. If in doubt consult Flowserve.
and all parts are free.
If there is any possibility of the system allowing the
Recheck the coupling alignment, as previously pump to run against a closed valve or below
described, to ensure no strain on coupling is due to minimum continuous safe flow a protection device
pipe. If pipe strain exists, correct piping. should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.
4.8 Electrical connections
If there are any circumstances in which the system
Electrical connections must be made by can allow the pump to run dry, or start up empty, a
a qualified Electrician in accordance with relevant power monitor should be fitted to stop the pump or
local national and international regulations. prevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.

Page 22 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

If leakage of product from the pump or its associated j) Check torque of all bolting and the plugs for
sealing system can cause a hazard it is tightness
recommended that an appropriate leakage detection
system is installed. 5.1.1 Lubrication
Lubrication of bearing is by oil circulation into the
To prevent excessive surface temperatures at bearing housing provided by oil ring, slinger or pure
bearings it is recommended that temperature or oil mist. A constant level oiler is normally furnished
vibration monitoring are carried out. See sections (except for pure oil mist lubrication) with the pump
5.7.4 and 5.7.5. unless otherwise specified.

5 COMMISSIONING, START-UP, 5.1.1.1 Oil ring or Slinger Lubrication


OPERATION AND SHUTDOWN Before filling the bearing housing reservoir, flush out
the housing thoroughly with safety solvent and a
leading grade of flushing oil, compatible with the
These operations must be carried lubricating oil that will be used. The reservoir is to be
out by fully qualified personnel. filled to appropriate level as illustrated in section
5.1.1.1.5
5.1 Pre-commissioning procedure
The following steps should be followed at initial start
up and after the equipment has been overhauled:
a) Prior to installing the pump, flush the suction side
of the system to remove all deposit (slag, bolts
etc).
b) Ensure the pump and piping is clean. Before
putting the pump into operation, the piping should
be thoroughly back flushed to remove any foreign
matter which may have accumulated during
installation. Take all possible care not to
contaminate your system.
c) Install suction strainer if required. (See Section Figure 5.1
4.6.2.1).
d) Fill the bearing housing with the appropriate oil to
the correct level. Bearing must receive a small
amount of oil prior to starting to ensure adequate
lubrication at start up. (Refer to Section 5.1.1).
e) Turn pump rotor by hand or with a strap wrench
to make sure it turns smoothly.
f) Assure that correct seal piping has been installed
and has not been damaged.
g) Prior to coupling installation, bump start motor to
check for correct rotation. If rotation is not correct
refer to motor manual for appropriate connections Figure 5.1
to change rotation (Shut down all power prior to
change). D1: oiler connection with slinger lubrication
h) Ensure coupling is correctly aligned and C1: overflow plug with slinger lubrication
lubricated, and pump and driver is satisfactorily
doweled. (Refer to Section 4.5). D2: oiler connection with oil ring lubrication
i) Ensure coupling guard is correctly installed. C2: overflow plug with oil ring lubrication

The oil level must be maintained at the correct level:


The unit must not be operated unless oil lack may cause overheating and failure of the
coupling guard is securely and completely bolted bearings, while exceeding the correct level can result
in place. Failure to observe the warning could in leakage from the labyrinth seals. The constant
result in injury to operating personnel. level oiler can be adjusted by changing the height of

Page 23 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

the cross arms which support the glass reservoir, as


illustrated for TRICO oiler in section 5.1.1.1.1

The oil circulation is ensured by slinger or oil ring


according to the description as follow (see figure 5.2).

line bearing side lubrication


(1)-(2) the slinger (or oil ring if supplied) splash
the oil from the oil sump to the bearing housing
walls
(3)-(4) the oil is collected by the oil collector and
reaches the line bearing through the hole E
(5) the oil returns into the oil sump once it flows
into the line bearing

thrust bearings side lubrication


(1)-(2) the slinger (or oil ring if supplied) drives
the oil from the oil sump to the bearing housing
wall
(3)-(4) the oil is collected by the oil collector and
reaches the thrust bearing through the hole F
(6) the oil is collected behind the thrust bearings
and returns into the oil sump once it flows into the
thrust bearings
(7) the oil level is regulated by the overflow hole
G. Through this hole the oil returns into the
sump.

Figure 5.2

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

5.1.1.1.1 Trico oiler setting (standard)


a) Initial fill via top of housing, using overflow plug to
establish correct level (see Section 5.1.1.1
illustration).
b) Release thumb screw and remove bottle.
Establish a measurement from the centre line of Figure 5.4
Sight glass
the oiler connection in bearing housing to the
upper cross arm of 6 mm (0.24 in.); this can be
obtained by completely screwing down the lower 5.1.1.1.3 Replenishment
arm as illustrated on figure 5.3. Replenish the oil in the oiler as required. More
c) Fill bottle with recommended oil and install on frequent replenishment at high temperatures may be
holder. Remove and fill bottle as many times as is required.
required to fill the bearing housing up to the cross
arm level and no air bubbles appear in the bottle. 5.1.1.1.4 Oil change
d) Remove bottle and ascertain that the oil level is 6 Frequency of oil change is dependent on pump
mm (0.24 in.) from the centre line of oiler service and environmental conditions. As a general
connection. Adjust upper cross arm as required guide, oil in the bearing housing should be changed
and lock in place with lower arm. every 4000 operating hours, after the initial change.

5.1.1.1.5 Lubrication Specification


The ideal bearing lubricant is a straight well refined,
neutral mineral, preferably of the turbine type. It
should not contain free acid, chlorine sulphur or more
than a trace of free alkali. It is suggested that the oil
conform to the following physical characteristics.

5.1.1.2 Pure Oil Mist Lubrication


If the pump bearing housing is arranged for pure oil
mist lubrication the following connections are
provided in the bearing housing:

- NPT with adapter oil mist inlet connection in


the top half of the bearing housing, between line
and thrust bearings.
- NPT vent connection in the space between
the rolling element bearing and the
inboard/outboard bearing housing cover.
Figure 5.3 - NPT drain connection in the bottom half of the
5.1.1.1.2 Inspection bearing housing.
Inspect the oil level in the bearing housing at least
once a day. Inspect the condition of the oil at least Remove inlet and outlet pipe plugs from above
weekly. Oil is always subject to gradual deterioration connections. Install appropriate reclassifier in the top
from use and contamination from dirt and moisture opening, leave open vent connections, connect oil
which is the cause of premature bearing wear. recovery trap to bottom opening or leave it open to
act as a relief. Refer to Figure 5.5 for details.
For oil lubricated pumps, fill the
bearing housing with correct grade of oil to the
correct level, i.e. constant level oiler bottle (standard
configuration) and sight glass (when fitted on
request).

Page 25 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

- NPT with adapter oil mist inlet connection in


the top half of the bearing housing, between line
and thrust bearings.
- NPT vent connection in the space between
the rolling element bearing and the
inboard/outboard bearing housing cover.
- NPT drain connection in the bottom half of the
bearing housing.

Remove inlet and outlet pipe plugs from above


connections. Install appropriate reclassifier in the top
opening, leave open vent connections, connect oil
recovery trap to bottom opening or leave it open to
act as a relief. Refer to Figure 5.5 for details.
Also this configuration include the internals like
slinger or oil ring as specified in section 5.1.1.1 and a
Figure 5.5 special constant level oiler designed for the Purge
arrangement.
No oil ring, slinger or constant level oiler are supplied.

5.1.1.3 Purge Oil Mist Lubrication


If the pump bearing housing is arranged for purge oil
mist lubrication the following connections are
provided in the bearing housing:

Page 26 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

5.2 Pump Lubricants


5.2.1 Recommended oil lubricants

Oil Oil Ring or Slinger Lubrication Pure Oil Mist


Lubrication
Lubrication service Ball Bearing
Type Mineral Oil Mineral Oil
Centrifugal Pump Lubrication

(Petroleum Based) (Petroleum Based)


Viscosity
32 46 68 100
mm /s 40 C [cSt]
Oil temperature range * -5 to 65 up to 75 up to 85 -30 and above
C (F) (-23 to 149) (up to 167) (up to 185) (59 and above)
Approx. Consumption 0.12 litres / month 0.12 litres / month 0.12 litres / month 0.12 litres / month
continuous operation pint per month pint per month pint per month pint per month
Running in Period 500 hours 500 hours 500 hours 500 hours
First Oil Charge 500 hours 500 hours 500 hours 500 hours
Further Oil Changes 4000 hours 4000 hours 4000 hours 4000 hours
One Year Consumption 1.44 litres approx. max 1.44 litres approx. max 1.44 litres approx. max 1.44 litres approx. max
Designation according to
32 46 68 100
DIN51502 ISO VG
BP Energol HL32 BP Energol HL46 BP Energol HL68
BP -
BP Energol HLP32 BP Energol HLP46 BP Energol HLP68
CASTROL
Perfecto T32 Perfecto T46 Perfecto T68 -
DEA
Anstron HL32 Anstron HL46 Anstron HL68
-
Anstron HLP32 Anstron HLP46 Anstron HLP68
Elf OLNA 32
HYDRELEF 32 TURBELF SA46 TURBELF SA68
-
Oil Companies and Lubricants

TURBELF 32
ELFOLNA DS32 ELFOLNA DS46 ELFOLNA DS68
Esso TERESSO 32 TERESSO 46 TERESSO 68
-
NUTO H32 NUTO H46 NUTO H68
LSC LSO 32 LSO 46 LSO 68 LSO 100
(for oil mist) Synthetic oil Synthetic oil Synthetic oil Synthetic oil
Mobil Mobil DTE oil light Mobil DTE oil medium Mobil DTE oil heavy
Mobil DTE13M Mobil DTE15M medium -
MobilDTE24 Mobil DTE25 Mobil DTE26
Q8 Q8 Verdi 32 Q8 Verdi 46 Q8 Verdi 68
-
Q8 Haydn 32 Q8 Haydn 46 Q8 Haydn 68
Shell Shell Tellus 32 Shell Tellus 01 C 46 Shell Tellus 01 C68
Shell Tellus 37 Shell Tellus 01 46 Shell Tellus 01 68 -
Shell Turbo T32 Shell Turbo T46 Shell Turbo T68
Texaco Rando Oil HD 32 Rando Oil 46 Rando Oil 68
-
Rando Oil HD-AZ-32 Rando Oil HD B-46 Rando Oil HD C-68
Total Azolla ZS32 Azolla ZS46 Azolla ZS68 -
Wintershall Wiolan HN32 Wiolan HN46 Wiolan HN68
-
(BASF Group) Wiolan HS32 Wiolan HS46 Wiolan HS68
(*) Note that it normally takes 2 hours for bearing temperature stabilize and the final temperature will depend on the ambient, r/min,
pumpage temperature and pump size. Also some oils have a greater Viscosity Index than the minimum acceptable of 95 (e.g. Mobil
DTE13M) which may extend the minimum temperature capability of the oil. Always check the grade capability where the ambient is less
than -5 C (-23 F).

Page 27 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

checked against the order. There may be


If a synthetic lubricant (fire resistant fluid) is to be requirements for an external clean supply, particular
used instead of the normal type oil for the lubrication supply pressure or the commencement of lubrication
of bearings, gears etc., the material of all gaskets and supply before pump start-up.
"O" rings in contact with the lubricant must be
compatible with the lubricant. Normal gasket
materials will usually swell and deteriorate when 5.2.4 Lubrication schedule
immersed in synthetic lubricants: also normal paints
5.2.4.1 Oil lubricated bearings
will peel from internal walls of reservoirs and bearing Normal oil change intervals are 4000 operating hours
chambers. or at least every 6 months. For pumps on hot service
In case of Pure Oil Mist lubrication the lubricant oil or in severely damp or corrosive atmosphere, the oil
should be rust and oxidation inhibited and stray mist will require changing more frequently. Lubricant and
suppressed, manufactured in accordance with good bearing temperature analysis can be useful in
commercial practice. The viscosity should be ISO VG optimising lubricant change intervals.
100. Recommended Oil Suppliers are according to The lubricating oil should be a high quality mineral oil
the previous list having foam inhibitors. Synthetic oils may also be
used if checks show that the rubber oil seals will not be
5.2.2 Recommended fill quantities adversely affected.
Based on the specified operating conditions and an
Bearing Housing Bearing Oil Fill Capacities litres (fl. oz.) ambient temperature of 43C (110F) for ring-oiled or
Size (*) Designation Slinger Oil Ring splash systems, oil sump temperature below 82C
G040B159 3108 1.51 (51.05) 1.13 (38.21)
(180F) is expected.
G050B159 31311/31313 1.34 (45.31) 0.85 (28.74)
G070B159 31314 1.83 (61.87) 1.02 (34.49)
G090B159 31315 4.43 (149.78) 2.82 (95.34) A continuously rising temperature, or an abrupt rise,
G090B159 31316 4.17 (140.99) 2.60 (87.91) indicates a fault.
Oil Slinger or Oil Ring
* The bearing housing size can be identified from the 5.3 Direction of rotation
identifying marks cast on the housing on the
horizontal centre line in the opposite side to the oiler Ensure the pump is given the same
and from the thrust bearing side indicated by rotation as the pump direction arrow fit on bearing
nameplate. housing. In any case the direction of rotation must be
checked with the pump disconnected.
Bearing Housing Oil Consumption
Bearing
Size (*) l/min cc/min
Designation
(gall/min)
3
(inch /min) To avoid dry running the pump must either be filled
G040B159 3108 6 (1.58) 0.024 (0.0015) with liquid or have the flexible coupling disconnected
G050B159 31311/31313 8.5 (2.24) 0.034 (0.002) before driver is switched on.
G070B159 31314 11 (2.9) 0.044 (0.0027)
G090B159 31315 11 (2.9) 0.044 (0.0027) If maintenance work has been carried
G090B159 31316 12.5 (3.3) 0.05 (0.003) out to the site's electricity supply, the direction of
Pure and Purge Oil Mist
rotation should be re-checked as above in case the
supply phasing has been altered.
5.2.3 Bearing housing oil limitations

Recommended Oil Temperature At Start Up 15.6 C 5.4 Guarding


60 F
Desirable Operating Temperature 60-71 C Guarding is supplied fitted to the pump set. If
140-160 F this has been removed or disturbed ensure that all the
Oil Level Above Oil Connection Centre line 6 mm protective guards around the pump coupling and
exposed parts of the shaft are securely fixed.
When the starting temperature is below -10 C (14
F) for long time its suggested to use synthetic oil.
Other drivers and gearboxes, if appropriate, should
be lubricated in accordance with their manuals. 5.5 Priming and auxiliary supplies

In the case of product lubricated Ensure all electrical, hydraulic,


bearings the source of product supply should be pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.

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HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

g) Check that pump is vented by observing leakage


from casing vent (when fitted) and seal piping
Ensure the inlet pipe and pump casing vent. Close vent (if fitted) when liquid is emitted.
are completely full of liquid before starting continuous h) Turn on cooling liquid and assure correct flow
duty operation. exists (to cooler, insert gland etc.) as specified.
i) Double check pump rotation by starting unit
momentarily. The direction of input shaft
Before starting or while operating the rotation is counter clockwise when facing
pump, the casing and suction line must be completely pump shaft from coupling end. Ensure that
filled with the liquid being pumped. The rotating parts the pump coasts down to a gradual stop.
depend on this liquid for lubrication and the pump
may seize if operated without liquid.
If pump stops abruptly when driver
5.6 Starting the pump is shut down, investigate for pump binding. Take
a) Close discharge valve if valve is not already necessary remedial action before resuming
closed, and then crack open to assure minimal operation.
flow. (Do not start unit with fully closed valve). On
first starts care must be taken not to cause a j) Start the driver and bring it up to speed quickly.
system water hammer. k) As soon as the pump is up to rated speed slowly
b) Prepare the driver for start up in accordance with open discharge valve.
the driver manufacturer's instructions. l) This will avoid abrupt changes in velocity and
c) Warm up pump (if applicable). prevent surging in the suction line.
d) Avoid severe thermal shocks to the pump as the m) Perform the operating checks
result of sudden liquid temperature changes. The
pump must be preheated prior to start up. Unless 5.7 Operating checks
otherwise specified the thermal temperature of
the casing must be within 55 C (130 F) of the In the interest of operator safety the unit
temperature of the liquid to be pumped at time of must not be operated above the nameplate
start up. Due to the heavy metal sections, the conditions. Such operations could result in unit
casing will lag the liquid temperature during such failure causing injury to operating personnel.
changes, and severe temperature stresses and Consult user instruction book for correct
subsequent misalignment of machined fits may operation and maintenance of the pump and its
result. Preheating is accomplished by circulating supporting components.
a small amount of hot fluid through the casing by
utilising vents, drains or bypass from discharge.
Preheat pump slowly at a rate not to exceed 55 Operation at low flows results in
C per hour (130 F per hour). pump heating the liquid. A bypass may be
e) Prime pump and ensure suction valve is open. required to prevent vaporisation and subsequent
pump damage. Refer to local FLOWSERVE
branch to determine if a bypass is required.
Ensure flushing and/or cooling/ Mechanical damage may result from continuous
heating liquid supplies (if required) are turned ON operation at flows less than the specified
before starting the pump. minimum continuous stable flow.

Immediately after start up, and frequently during


Before starting or while operating
running check the following:
the pump, the casing and suction line must be
completely filled with the liquid being pumped.
a) Check suction and discharge pressure gauges.
The rotating parts depend on this liquid for
b) Check pressure gauges on each side of suction
lubrication and the pump may seize if operated
strainer.
without liquid.
c) Check for excessive leakage at seal areas.
d) Check for unusual noises.
f) Ensure pump recirculating line (if required) is
e) Check oil level in bearing housing. (Refer to
open, clear and free of obstructions.
Section 5).

Page 29 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

set the alarm at 93 C (180 F) and the trip at 105


Operation of the unit without correct C (200 F)
lubrication can result in overheating of the
bearings, bearing failures, pump seizures and It is important, to keep a check on bearing
actual break-up of the equipment exposing temperatures. After start up the temperature rise
operating personnel to physical injury. should be gradual, reaching a maximum after
approximately 1.5 to 2 hours. This temperature rise
f) Check for vibrations. should then remain constant or marginally reduce
g) Check for adequate flow of cooling liquids. with time.
h) Check for hot alignment: for services 55 C (130
F) and more above ambient, after unit has been 5.7.4 Normal vibration levels, alarm and trip
operated a sufficient period of time to reach For guidance, pumps generally fall under a
normal operating temperature and condition, the classification for rigid support machines within the
unit is to be shut down and a "HOT" coupling International rotating machinery standards and the
alignment check must be made (Refer to Section recommended maximum levels below are based on
4.5.4). those standards.

5.7.1 Venting the pump Alarm and trip values for installed
pumps should be based on the actual measurements
Vent the pump to enable all trapped air to (N) taken on the pump in the fully commissioned as
escape taking due care with hot or hazardous liquids. new condition. Measuring vibration at regular
intervals will then show any deterioration in pump or
Under normal operating conditions, after the pump system operating conditions.
has been fully primed and vented, it should be
Vibration velocity unfiltered HPX
unnecessary to re-vent the pump. mm/s (in./s) r.m.s. mm/s (in./s) r.m.s.
5.7.2 Pumps fitted with mechanical seal Normal N 5 (0.2)
Mechanical seals require no adjustment. Any slight Alarm N x 1.25 6.2 (0.25)
initial leakage will stop when the seal is run in. Shutdown trip N x 2.0 10 (0.4)

Before pumping dirty liquids it is advisable, if 5.7.5 Stop/start frequency


possible, to run in the pump mechanical seal using Pump sets are normally suitable for the number of
clean liquid to safeguard the seal face. equally spaced stop/starts per hour shown in the
table below. Check actual capability of the driver and
External flush or quench should be control/starting system before commissioning.
started before the pump is run and allowed to flow for
a period after the pump has stopped. Motor rating kW (hp) Maximum stop/starts
per hour
Never run a mechanical seal dry, even Up to 15 (20) 15
for a short time. Between 15 (20) and 90 (120) 10
5.7.3 Bearings Above 90 (120) 6

If the pumps are working in a potentially Where duty and standby pumps are installed it is
explosive atmosphere temperature or vibration recommended that they are run alternately every
monitoring at the bearings is recommended week.

If bearing temperatures are to be monitored it is 5.8 Normal Start Up


essential that a benchmark temperature is recorded The starting procedure to be followed for normal start
at the commissioning stage and after the bearing up is the same as that for initial starting with the
temperature has stabilised (see 5.2.4.1 for exception that Step (i) section 5.3 "CHECK
temperature limits). ROTATION" does not have to be repeated as long as
When a oil temperature sensor is provided: driver systems have not been changed since last
set the alarm at 82 C (180 F) and the trip at 90 pump operation.
C (194 F) for high ambient temperature and/or
hot service
When the bearing temperature sensor is provided:

Page 30 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Before restarting the machine, the relevant


5.9 Stopping the pump instructions listed in section 5, Commissioning, start
up, operation and shut down must be observed.
a) Shut down driver.

The pump should be shut Oil and grease leaks may make the ground
down rapidly to protect the internal wearing slippery. Machine maintenance must always
parts which are lubricated by the liquid being begin and finish by cleaning the ground and the
pumped. exterior of the machine.

If platforms, stairs and guard rails are required for


If pump stops abruptly when driver is maintenance, they must be placed for easy access to
shut down, investigate for pump binding. Take areas where maintenance and inspection are to be
necessary remedial action before restarting carried out. The positioning of these accessories
pump. must not limit access or hinder the lifting of the part to
be serviced.
b) Close the pump suction and discharge valve.
c) Close valve in bypass line When air or compressed inert gas is used in the
d) Turn off cooling liquid. maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
e) If pump is subjected to freezing protection.
temperatures the pump must be drained of
liquid to prevent damage to the pump. Do not spray air or compressed inert gas on skin.

5.10 Hydraulic, mechanical and Do not direct an air or gas jet towards other people.
electrical duty
This product has been supplied to meet the Never use air or compressed inert gas to clean
performance specifications of your purchase order, clothes.
however it is understood that during the life of the
product these may change. The notes on section 3.4 Before working on the pump, take measures to
may help the user decide how to evaluate the prevent an uncontrolled start. Put a warning board
implications of any change. If in doubt contact your on the starting device with the words:
nearest Flowserve office. "Machine under repair: do not start".

With electric drive equipment, lock the main switch


6 MAINTENANCE open and withdraw any fuses. Put a warning board
on the fuse box or main switch with the words:
6.1 General "Machine under repair: do not connect".

It is the plant operator's responsibility to ensure


that all maintenance, inspection and assembly work Before attempting any inspection or
is carried out by authorised and qualified personnel repair on the pump, the driver controls must be in the
who have adequately familiarised themselves with "off" position, locked and tagged to prevent injury to
the subject matter by studying this manual in detail. personnel performing service on the pump.
(See also section 1.6)
Before attempting to disassemble pump, pump
must be isolated from system, by closing suction and
Any work on the machine must be performed when it discharge system valves, drained of liquid and
is at a standstill. It is imperative that the procedure cooled, if pump is handling hot liquid.
for shutting down the machine is followed, as
described in section 5.9. Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
On completion of work all guards and safety devices fumes when using cleaning agents.
must be re-installed and made operative again.

Page 31 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

f) Check all lubricant levels i.e. bearing housing


6.2 Maintenance schedule oilers, seal Plan 52/53, seal supply systems as
applicable.
It is recommended that a maintenance plan and g) On grease lubricated pumps, check running
schedule is adopted, in line with these User hours since last recharge of grease or complete
Instructions, to include the following: grease change.
a) Any auxiliary systems installed must be h) Check any auxiliary supplies eg heating/cooling
monitored, if necessary, to ensure they function (if fitted) are functioning correctly.
correctly. i) Check stand by pump is at applicable
b) Check for any leaks from gaskets and seals. The temperature and available to start as required.
correct functioning of the shaft seal must be
checked regularly.
c) Check bearing lubricant level, and if the hours
Refer to the manuals of any associated
equipment for routine checks needed.
run show a lubricant change is required.
d) Check that the duty condition is in the safe 6.2.2 Periodic inspection (monthly)
operating range for the pump. a) Check for lubricant contamination whether
e) Check vibration, noise level and surface bearing oil, or seal oil (if applicable) by sample
temperature at the bearings to confirm analysis.
satisfactory operation. b) Check all paint or protective coatings.
f) Check dirt and dust is removed from areas c) Check all power/instrument cable glands for
around close clearances, bearing housings and tightness.
motors.
g) Check coupling alignment and re-align if
necessary.
Refer to the manuals of any associated
equipment for periodic checks needed.
FLOWSERVE specialist service personnel can help
with preventative maintenance records and provide 6.2.3 Periodic inspection (six monthly)
condition monitoring for temperature and vibration to
identify the onset of potential problems. a) Check foundation bolts for
security of attachment, corrosion. Check grouting
If any problems are found the following sequence of for looseness, cracking or general distress.
actions should take place: b) Change lubricants.
a) Refer to section 7, Faults; causes and remedies, c) Check calibration of instruments.
for fault diagnosis. d) The coupling should be checked for correct
b) Ensure equipment complies with the alignment and worn driving elements.
recommendations in this manual.
c) Contact Flowserve if the problem persists. Refer to the manuals of any associated
equipment for periodic checks needed.
6.2.1 Routine inspection (daily/weekly)
6.2.4 Inspection (after 3 years)
The following checks should be made a) Check internal condition of pump and all ancillary
and the appropriate action taken to remedy any pipework for corrosion/erosion.
deviations: b) Check internal pump components for wear.
a) Check suction and discharge gauges. c) Change bearings
b) Check for abnormal operating conditions
(High/Low Temperature, Flows, Vibration, 6.2.5 Re-lubrication
Pressures Etc.) Lubricant and bearing temperature analysis can be
c) Check motor current/driver power. useful in optimising lubricant change intervals. In
d) Check that there are no abnormal fluids or general however, the following is recommended.
lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) are full and 6.2.5.1 Oil lubrication
operating normally.
e) Check that shaft seal leaks are within acceptable Maintaining the correct oil level is very
limits. important.

Page 32 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

If the pump is supplied with a constant level oiler the For normal maintenance:
oil level will be automatically maintained and as long 1 - Set of bearings (line and thrust)
as oil is visible in the glass bottle there is no need to 2 - Sets of gaskets and o-ring
refill. If however a sight glass has been fitted then 2 - Wear rings set (2 rotating + 2 stationary)
regular checks should be made to ensure the level is 1 - Mechanical seals
maintained at the centre of the glass window. 1 - Labyrinth and deflector set
(drive and impeller end)
Refer to section 5.1.1 for methods of oil fill, section 1 - Shaft
5.2.1 for oil grade recommendations and 5.2.4 for the 1 - Impeller
schedule and temperature limits.
6.5 Tools required
6.2.6 Mechanical seals
No adjustment is possible. When leakage reaches A typical range of tools that will be required to
an unacceptable level the seal will need replacement. maintain these pumps is listed below.
Readily available in standard tool kits, and dependent
6.3 Spare parts on pump size:
Open ended spanners (wrenches) to suit up to
6.3.1 Ordering of spares 2 (M 50) screws/nuts
Flowserve keep records of all pumps that have been Socket spanners (wrenches), up to 2 (M 50)
supplied. When ordering spares the following screws
information should be quoted: Allen keys, up to 10 mm (A/F)
1) Pump serial number Range of screwdrivers
2) Pump size Soft mallet
3) Part name (a)
4) Part number (a)
5) Number of parts required
6.6 Fastener torques
(a) taken from the cross section drawing stored into
Steel Casing to Casing Cover
the job user instruction book and only in case not
B425 N08825 (Alloy 825)
available see at section 8. B473 S08020 (Alloy 20)
Torque Value
The pump size and serial number are shown on the Stud Size
Nm (lbft)
pump nameplate.
3/8 16UNC 9 (7)
To ensure continued satisfactory operation,
1/213UNC 25 (18)
replacement parts to the original design specification 5/8 11UNC 49 (36)
should be obtained from Flowserve. 3/4 10UNC 88 (65)
Any change to the original design specification 7/8 9UNC 137 (101)
(modification or use of a non-genuine part) will 1 8UNC 196 (145)
invalidate the pumps safety certification. 1 1/8 8UN 304 (224)
1 1/4 8UN 432 (318)
6.3.2 Storage of spares 1 3/8 8UN 589 (434)
1 1/2 8UN 785 (579)
Spares should be stored in a clean dry area away
1 5/8 8UN 1030 (759)
from vibration. Inspection and re-treatment of 1 3/4 8UN 1324 (976)
metallic surfaces (if necessary) with preservative is 1 7/8 8UN 1668 (1230)
recommended at 6 monthly intervals. 2 8UN 2060 (1519)
2 8UN 2992 (2206)
6.4 Recommended spares (according to 2 8UN 4120 (3038)

API)
For start up purposes:
1 - Set of bearings (line and thrust)
2 - Sets of gaskets and o-ring
2 - Wear rings set (2 rotating + 2 stationary)
1 - Mechanical seals
1 - Labyrinth set (drive and impeller end)

Page 33 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Bronze and Cast Iron Casing to Casing Cover


Steel Casing to Casing Cover
B148 C95200
A182 F51 (Duplex)
A276 S32760 (Super Duplex) Torque Value
Stud Size
B446 N06625 (Inconel 625) Nm (lbft)
A193 B8M Class 2
3/8 16UNC 10 (7)
Torque Value 1/213UNC 20 (14)
Stud Size
Nm (lbft) 5/8 11UNC 39 (29)
3/8 16UNC 25 (18) 3/4 10UNC 69 (51)
1/213UNC 59 (43) 7/8 9UNC 118 (87)
5/8 11UNC 118 (87) 1 8UNC 177 (130)
3/4 10UNC 196 (145) 1 1/8 8UN 265 (195)
7/8 9UNC 294 (217) 1 1/4 8UN 373 (275)
1 8UNC 491 (362) 1 3/8 8UN 491 (362)
1 1/8 8UN 687 (506) 1 1/2 8UN 687 (506)
1 1/4 8UN 981 (723) 1 5/8 8UN 883 (651)
1 3/8 8UN 1275 (940) 1 3/4 8UN 1128 (832)
1 1/2 8UN 1570 (1157) 1 7/8 8UN 1422 (1049)
1 5/8 8UN 2256 (1664) 2 8UN 1717 (1266)
1 3/4 8UN 2943 (2170) 2 8UN 2502 (1844)
1 7/8 8UN 3787 (2792) 2 8UN 3434 (2534)
2 8UN 4415 (3255)
2 8UN 5886 (4340) Bronze and Cast Iron Casing to Casing Cover
2 8UN 7848 (5786) A536 60-40-18
A278 CL35
Steel Casing to Casing Cover Torque Value
Stud Size
A193 B7 Nm (lbft)
A193 B16
3/8 16UNC 15 (11)
B865 N05500 (Monel K 500)
17/4 PH A576 S17400 H1025 1/213UNC 29 (22)
5/8 11UNC 59 (43)
Torque Value 3/4 10UNC 108 (80)
Stud Size
Nm (lbft) 7/8 9UNC 177 (130)
3/8 16UNC 29 (22) 1 8UNC 265 (195)
1/213UNC 78 (58) 1 1/8 8UN 392 (289)
5/8 11UNC 147 (108) 1 1/4 8UN 589 (434)
3/4 10UNC 245 (181) 1 3/8 8UN 785 (579)
7/8 9UNC 392 (289) 1 1/2 8UN 1030 (759)
1 8UNC 638 (470) 1 5/8 8UN 1324 (976)
1 1/8 8UN 883 (651) 1 3/4 8UN 1717 (1266)
1 1/4 8UN 1226 (904) 1 7/8 8UN 2109 (1555)
1 3/8 8UN 1668 (1230) 2 8UN 2600 (1917)
1 1/2 8UN 2060 (1519) 2 8UN 3777 (2785)
1 5/8 8UN 2943 (2170) 2 8UN 5052 (3725)
1 3/4 8UN 3728 (2749)
1 7/8 8UN 4905 (3617) Bearing Housing to Casing Cover
2 8UN 5396 (3978) Torque Value
2 8UN 7848 (5786) Hex Head
Screw Size Nm (lbft)
2 8UN 10497 (7739)
1/2 18-22 (13-16)
5/8 37-45 (27-33)

Bearing Housing End Cover to Bearing Housing


Torque Value
Hex Head
Screw Size Nm (lbft)
3/8 8-11 (6-8)

Page 34 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Mechanical Seal to Casing Cover Before attempting any maintenance work on


Torque Value pumps in vacuum service, the pumps must be
Stud/Nut Size
Nm (lbft) isolated from suction and discharge system then
1/2 35-41 (26-30) carefully vented to return pressure in pump
5/8 58-68 (45-50) casing to atmospheric pressure.
3/4 130-150 (95-110)

Thrust Bearing Locknut Remove the pipe plug(s) from the


Torque Value top of the bearing housing(s) and check to see
Bearing Size
Nm (lbft) that oil rings are riding free on the pump shaft
31307 37 39 (27 29) and are not hung up. Failure to observe this
31308 50 53 (37 39) caution could result in damage to or destruction
31309 65 68 (48 50) of equipment.
31310 81 85 (60 63)
31311 99 104 (73 77) 6.7.1 Disassembly of Pull Out Element
31312 118 125 (87 92) This is a pull from rear design, so it is not necessary
31313 138 145 (102 107)
to remove casing, or to detach suction or discharge
31314 159 167 (117 123)
31315 180 190 (133 140) piping, coupling hubs or to remove driver.
31316 203 214 (150 158)
a) Remove all seal piping, related instrumentation
and electrical equipment that will interfere with
Inboard/Outboard Flingers & Oil Thrower disassembly. Drain pump casing.
Torque Value
Socket Head
Capscrew Size Nm (lbft)
When pump is handling "hot" liquid extreme
1/4 4-5 (3-4) care must be taken to ensure safety of personnel
when attempting to drain pump. Hot pumps must
Torque Values listed above are selected to achieve be allowed to cool before draining.
the correct amount of pre-stress in the threaded
fastener. Maintenance personnel must ensure that
threads are in good condition (free of burrs, galling, When pump is handling "caustic" liquid
dirt, etc.) and that commercial thread lubricant NILS extreme care must be taken to ensure safety of
Wega 2 containing molybdenum disulfide is used. personnel when removing auxiliary piping or
Torque should be periodically checked to ensure that when draining pump. Protective devices of
it is at the recommended value. suitable protective materials must be worn when
draining the pump.
6.7 Disassembly
b) Disassemble and remove coupling guard and
Refer to section 1.6, Safety, before dismantling coupling spacer.
the pump. c) Place lifting straps around bearing bracket at seal
area. Take a slight strain on slings.

Before dismantling the pump for


overhaul, ensure genuine Flowserve replacement
parts are available.

Refer to sectional drawings for part


numbers and identification.

Before attempting to disassemble the pump,


the pump must be isolated from the system, by
closing suction and discharge system valves, Figure 6.1
drained of liquid and cooled, if pump is handling location of lifting straps for removing pumping element
hot liquid.

Page 35 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

d) Drain the bearing housing of oil. This can be (with the gland plate uppermost). Note - When
done by removing the drain plug situated at the oil ring lubrication is provided an additional "
bottom of the bearing housing. NPT plug is fitted in the top of the bearing
housing adjacent to the mushroom headed vent.
Removal of the plug should enable the visual
Use caution when draining hot oil from inspection of the ring.
bearing housing to prevent burns/injury to h) Remove mechanical seal cartridge assembly.


personnel
Refer to any special instructions supplied with
e) It is advisable to thoroughly drain and dry off the
baseplate before attempting any maintenance the mechanical seal.
work on the pump.
6.7.1.2 Bearing housing disassembly
This could eliminate the risk of slipping a) Looking at the bearing housing, remove impeller
on a wet surface causing personal injury or key (and throat bush if fitted). If a cooling fan is
mechanical damage. fitted, then remove the three locking screws
securing the fan to the outboard deflector.
f) Remove casing cover to casing main flange Withdrawal the fan from the coupling end of the
bolting. Install two jack screws (provided) in shaft.
casing cover. Tighten jack screws evenly to b) Loosen clamping screws and remove both the
separate joint between casing cover and casing. deflectors from pump shaft.
g) Carefully withdraw pumping element from casing c) Remove cap screws from bearing end covers,
until impeller (or inducer when fitted) is clear of securing cover to bearing housing.
casing. Move pumping element to area where d) Remove bearing end covers remove and discard
disassembly will be performed. gasket. Remove labyrinth from bore of outboard
h) Correctly support pumping element in horizontal end cover. Remove o-ring from labyrinth.
position. For non-inducer machines release e) Place the bearing housing in a vertical position,
impeller locking screws and locknut on impeller. (coupling end up) on blocking. Blocking must be
For machines fitted with an inducer, release cap of sufficient height to prevent shaft end from
nut then remove security washer. contacting the floor. To avoid damage to the oil
rings, (when fitted) position them as shown.
Locking devices have left hand
thread form
i) Remove inducer (if fitted) and impeller.
j) Remove and discard gasket from casing cover.
Now rotate assembly so that the shaft axis is in
the vertical plane with coupling end uppermost.

6.7.1.1 Mechanical seal disassembly


a) Refer to mechanical seal drawing (in the jobs
user instruction) and identify the seal setting
plates on the front of the gland plate.
b) Rotate (or slide as appropriate for the design) the
plates into the mechanical seal sleeve setting
groove and then secure.
c) Slacken the screws locking the collar/seal sleeve
onto the pump shaft.
d) Unscrew any pipework from the tapped ports on
the periphery of the gland plate.
e) Remove the cap screws which secure the casing
cover to the bearing housing.
f) With the casing cover suitably supported carefully Figure 6.2
remove the bearing housing and place
horizontally on flat surface. f) Remove the shaft assembly from coupling end of
g) Remove the four nuts securing the gland plate to bearing housing. Remove labyrinth from seal end
the casing cover. Returning to the casing cover of bearing housing. Remove o-ring from labyrinth.

Page 36 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Take care not to damage the oil 6.8.5 Gaskets and O-rings
rings. After dismantling, discard and replace.

g) Release locking tab of lock washer. Remove 6.8.6 Bearings


locknut, lock washer and spacer. a) It is recommended that bearings are not re-used
h) Bearings can be removed by the use of a press after any removal from the shaft. In any case the
or puller. Bearing must be installed in the same bearings must be replaced not after 25000
manner as removed. It is suggested that each operating hours.
bearing be marked for sequence and direction. b) If the bearing cannot be removed with the tools
available never use a torch under any
When removing bearings exert circumstances. Split the outer ring with a small
pressure on inner race only. Do not exert any hand grinder, saw through the ball/roller retainer,
pressure on outer bearing race. (See Section and split the inner ring about three quarters
7.6). through with a grinder and break with a cold steel
chisel.
i) Remove oil rings and oil throwers from the shaft
as appropriate. Do not attempt to inspect condition
j) Check the shaft for run out using "V" blocks or of bearings until they have been cleaned.
rollers placed under the bearing areas. Run out
of shaft is not to exceed 0.05 mm TIR (0.002 c) Solvent for cleaning bearings should be in a
in.TIR). clean container. Place bearings in solvent and let
soak for a short time. Agitate the bearing around
6.8 Examination of parts near the top of the container, giving it a turn now
and then until it is clean. Rinse in a clean
Used parts must be inspected before container of fresh solvent.
assembly to ensure the pump will subsequently run
properly. Do not spin dirty bearings. Rotate
In particular, fault diagnosis is essential to enhance them slowly while washing.
pump and plant reliability.
d) Dry thoroughly cleaned bearings. If an air hose is
6.8.1 Casing, seal housing and impeller used for drying, make sure it is clean dry air.
a) Inspect for excessive wear, pitting, corrosion,
erosion or damage and any sealing surface Do not allow the bearings to spin by
irregularities. force of air. Hold the inner and outer rings to
b) Replace as necessary. prevent bearing from spinning.

6.8.2 Mechanical seal e) Inspect bearings immediately. If there is any


a) Mechanical seal stationary and rotating faces question as to the condition of a bearing do not
should be inspected for signs of wear or cracks hesitate to replace it. There are many conditions
and replaced as necessary. that contribute to the deterioration of the
b) It is recommended that when reassembling bearings. A qualified bearing representative
mechanical seal new "O" rings and gaskets be should be consulted if there is any question of
used. bearing condition.
c) Refer to manufacturers drawing for assembly of f) Inspected bearings which will be reused should
mechanical seal. Refer to mechanical seal be packed with new grease or dipped in clean
section within this manual for further details. lubricating oil, covered with clean lint free rags or
other suitable covering and placed in a clean box
6.8.3 Throat Bush (If fitted) or carton until ready for installation.
a) Check the throat bush and replace if required.
Note that the bush outside diameter should be Under no circumstances the
the same diameter as the adjacent impeller wear bearings are to be left exposed.
ring.
6.8.7 Labyrinths or bearing isolators (if fitted)
6.8.4 Shaft a) The lubricant, bearings and bearing housing
Replace if grooved, pitted or worn. seals are to be inspected for contamination and

Page 37 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

IMPELLER
damage. If oil bath lubrication is utilised, these
provide useful information on operating
conditions within the bearing housing. IMPELLER
RING
HAND
b) If bearing damage is not due to normal wear and GRINDER

the lubricant contains adverse contaminants, the


cause should be corrected before the pump is
returned to service.
c) Labyrinth seals and bearing isolators should be
inspected for damage but are normally non-
wearing parts and can be re-used. Figure 6.3
d) Bearing seals are not totally leak free devices.
Oil from these may cause staining adjacent to the b) Make sure ring fits on impeller are free of nicks or
bearings. burrs. Heat new ring to 107 C (225 F) and
install on impeller. Drill and tap new holes in
impeller spaced half the circular distance from the
6.9 Assembly previously used holes in the impeller. See sketch
To assemble the pump consult the sectional
below.
drawings, see section 8, Parts list and drawings.

Ensure threads, gasket and O-ring mating faces are


clean.

6.9.1 Wear rings


The impeller may be fitted with both front and rear
wear rings or front ring only.
The impeller ring(s) are renewable and should be
replaced when badly grooved, and/or when pump
performance does not meet the system requirements.
Whenever it becomes necessary to replace either
wear ring, both rings involved (impeller and
casing/casing cover) must be ordered and replaced Figure 6.4
as a set as they are furnished standard size only.
Impeller wear rings when installed must
Spare impeller wear rings are supplied with a material
be machined to establish original diameter and
stock over outside diameter which has to be
running clearance. Whenever an impeller has new
machined off after rings fitting on impeller. If an
wear rings fitted it must be dynamically balanced
impeller with its wear rings is ordered as spare, it will
before being reassembled. Refer to the Cross
be supplied fully machined, including wear rings
Sectional drawing for the requested running
outside diameter, to original dimensions. Casing wear
clearance.
rings are always supplied fully machined. Be sure to
re-establish the original running clearance between
6.9.1.2 Case wear rings (and casing cover wear
the two wear rings involved by machining the fitted
ring when fitted)
impeller ring.
Each wear ring is locked against rotation with a
cylindrical pin.
6.9.1.1 Impeller wear rings
a) To remove the wear ring, press it out. If this
a) To remove impeller wear rings, mutually remove
method does not easily effect removal of the ring,
wear ring set screws or ground off tack weld.
it can be split apart. First, however, drill one or
Rings can be machined off or grind two slots
more holes in the face of the worn ring.
diametrically opposite across the width of the ring
b) New rings to be installed must be shrunk by
so it can be split apart. Use caution if ring is
freezing when installing in casing or casing cover.
removed by grinding so as not to damage
Fit and secure with a locking pin. Replacement
impeller hubs.
wear rings are furnished standard size in the
bore. Check the running clearance between
impeller and casing ring against the appropriate
value.

6.9.2 Oil Thrower(s) and Oil ring (if applicable)

Page 38 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

Install thrower(s) and oil ring (if supplied) onto shaft.


Secure thrower to shaft by tightening set screws into c) When bearings are installed on the shaft make
the location groove in the shaft. sure the bearing is installed squarely and is firmly
seated. Hold bearing in place until it has cooled
6.9.3 Bearings Housing sufficiently so that it will not move from position.
The--bearings require correct handling and Cover bearings to protect them from dirt.
installation to ensure optimum performance. The
following information is intended as a minimum to When installing the bearings the
ensure that the bearings are handled and installed mounting pressure should never be applied in
correctly. such a manner that it is transmitted through
the rolling element. Apply the mounting force
6.9.3.1 Bearings handling directly against, and only against, the inner
a) Do not remove new bearings from their storage ring.
package except for inspection, when stored for a
long period of time or just prior to their
installation. Inner thrust bearing must be
b) Work area must be clean to ensure that no dirt or assembled against shoulder on shaft with the
other contaminates will enter the bearings. wide flange of the inner race towards the
Handle bearings with clean, dry hands and with coupling. The outer thrust bearings is to be
clean, lint free rags. Lay bearings on clean paper placed on the shaft with the wide flange of the
and keep covered. Never expose bearings on a inner race towards the inner bearing.
dirty bench or floor.
c) Do not wash a new bearing. It is already clean
and the preservative should not be removed.
d) Before mounting, be sure shaft bearing areas are
clean and free of nicks and burrs. Check the
dimensions of these areas to ensure correct fit of
bearings.

6.9.3.2 Bearing installation


Install the thrust and radial bearings in the same
sequence and direction as removed.
There are two simple methods of providing a heat
source for expanding the inner race of the bearings to Figure 6.5
facilitate mounting.
a) In the first method, bearings still wrapped in their d) When installing bearings on shaft, a slight heat is
original intimate wrap are placed on a shelf in a required to expand the inner bearing race. The
temperature controlled oven, or in an enclosure use of a 150 watt (0.15 hp) light bulb with an
lined with foil and heated with electric light bulbs. aluminium foil cover to contain the heat is
A temperature of 66 C (150 F) for one half hour recommended. Place bulb foil to cover over
should be sufficient. bearing and light bulb. Heat for approximately 20
b) A second method consists of locating a light bulb - 30 minutes.
100 to 150 Watt ( 0.13 to 0.15 hp) in the bore of e) Install the spacer an then the lock washer and
the bearing. The light bulb will heat, primarily, the locknut.
inner ring and the bearing can usually be handled
by the outer ring without special gloves. Care
must be taken to keep the bearing clean and
uncontaminated.

The old and once popular method of


heating bearings in an oil bath is DEFINITELY
DISCOURAGED. HEATING INNER RING WITH
A GAS TORCH IS PROHIBITED. In either
case, it is difficult to control the heating rate
Figure 6.6
and final temperature and even more difficult
to keep the oil and/or bearing clean.

Page 39 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

f) Place the bearing housing in a vertical position on b) Rig bearing housing assembly to hoist impeller
blocks in preparation for installation of shaft end and shaft downwards. Carefully lower shaft
assembly. Make sure blocking is of sufficient end through seal sleeve until bearing housing
height so that shaft will not contact the floor. locates on casing cover.
g) Suspend shaft vertically for installation into c) Secure bearing housing to cover.
bearing housing. Position oil ring (if fitted) on d) Retighten mechanical seal drive collar set screws.
shaft to prevent damage it enters bearing Move setting plates from "transit" to "run"
housing. position. Refit screwed piping into mechanical
h) Lower the shaft assembly into the bearing seal gland plates.


housing. Install gasket and end cover. Insure that
the end cover is in contact with the outer cage of Refer to any special instructions supplied with
the bearings. Torque bolts in accordance with
the mechanical seal.
Section 6.6.
6.9.3 Casing assembly
a) For non-inducer machines install key and
impeller. Install locking nut - noting left hand
thread form. Torque nut to correct tightness. Fit
and tighten lockscrew on end of locknut throat
bush (if fitted).
b) Install a new spiral wound gasket into position on
casing cover.
c) Rig assembly with lifting straps to an overhead
hoist and carefully install the assembled pumping
element into the casing.

Use care when installing pumping


Figure 6.7 element to avoid damage to the gasket.
d) Install nuts on casing cover to casing studs.
i) Place bearing housing in a horizontal position Torque nuts evenly to correct tightness. (See
suitably supported. Fit new o-rings into the Section 6.6).
grooves on each labyrinth. Working from the e) Install coupling key and coupling hub onto the
coupling end of the shaft the smaller labyrinth pump shaft.
over the shaft and press into the bearing housing
until it locates against the machined shoulder. It
is held in place by the o-ring - no further fixing is The coupling hub has a shrink fit to
required. Repeat the operation for the other the pump shaft. The use of heat and an
labyrinth, working from the impeller end of shaft. approved press/puller will be required to
j) Install both the deflectors (impeller and coupling install it. Install the pump half coupling hub
end) onto shaft. Position flingers approximately 1 by heating to approximately 149 C (300 F) in
mm (0.040 in.) from their respective labyrinth and successive stages from periphery of hub
secure with appropriate clamping screws. toward the centre. NEVER APPLY AN OPEN
k) Check the axial play of the shaft, it must be FLAME TO THE COUPLING HUB TEETH.
limited to the internal bearing clearance. f) Re-install drain plug and fill the bearing housing
to the prescribed level with fresh lubricating oil.
6.9.4 Shaft seal (See Section 5.1.1).
g) Check to see if rotor runs freely by turning the
6.9.4.1 Shaft seal mechanical seal shaft with a strap wrench or by hand. Make any
a) Fit new gasket in face of mechanical seal gland corrections or adjustments.
plate. Refit mechanical seal cartridge over the 4 h) Check driver rotation. Driver rotation must
gland studs on the casing cover ensuring correct coincide with direction indicated by arrow on
orientation of the gland tappings (refer to pump.
mechanical seal assembly drawing). Secure with i) Align pump - motor coupling per "ALIGNMENT"
four nuts tightened to the torque specified in instructions and install spacer piece. Install
section 6.6. coupling guard.
j) Replace all auxiliary piping.

Page 40 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

7 FAULTS; CAUSES AND REMEDIES


FAULT SYMPTOM
P u m p o v e r h e a ts a n d s e i z e s
Bearings have short life
Pum p vi b ra t es o r i s noi sy

Mechanical seal has short life

Me cha ni ca l se al lea ks exc es si ve ly

Pump re qui res e xc es si ve p ow er

P u m p l o s e s p r i m e a f t e r s ta r t i n g

Insufficient pressure developed

In suf fi ci ent c apac ity del ive r ed

Pump does not deliver liquid



PROBABLE CAUSES POSSIBLE REMEDIES

A. System troubles
Pump not primed.
Check complete filling. Vent and/or prime.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Check NPSHa>NPSHr, proper submergence,
Insufficient margin between suction pressure and losses at strainers/fittings.
vapour pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and system.
Air or vapour pocket in suction line. Check suction line design for vapour pockets.
Air leaks into suction line. Check suction pipe is airtight.

Air leaks into pump through mechanical seal, Check and replace faulty parts.
sleeve joints, casing joint or pipe plugs. CONSULT FLOWSERVE.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.

Total head of system higher than differential head


of pump. Check system losses.
Total head of system lower than pump design Remedy or CONSULT FLOWSERVE.

head.
Specific gravity of liquid different from design.
Check and CONSULT FLOWSERVE.
Viscosity of liquid differs from that for which
designed.

Operation at very low capacity. Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.

Operation at high capacity. Measure value and check maximum permitted.


Remedy or CONSULT FLOWSERVE.

B. Mechanical troubles

Misalignment due to pipe strain. Check the flange connections and eliminate strains
using elastic couplings or a method permitted.

Improperly designed foundation. Check setting of baseplate: tighten, adjust, grout


base as required.

Page 41 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

7 FAULTS; CAUSES AND REMEDIES


FAULT SYMPTOM
P u m p o v e r h e a ts a n d s e i z e s
Bearings have short life
Pum p vi b ra t es o r i s noi sy

Mechanical seal has short life

Me cha ni ca l se al lea ks exc es si ve ly

Pump re qui res e xc es si ve p ow er

P u m p l o s e s p r i m e a f t e r s ta r t i n g

Insufficient pressure developed

In suf fi ci ent c apac ity del ive r ed

Pump does not deliver liquid



PROBABLE CAUSES POSSIBLE REMEDIES

Shaft bent. Check shaft runouts are within acceptable values.


CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.
Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.

Impeller damaged or eroded. Replace or CONSULT FLOWSERVE for improved


material selection.
Leakage under sleeve due to joint failure. Replace joint and check for damage.

Mechanical seal improperly installed. Check alignment of faces or damaged parts and
assembly method used.

Incorrect type of mechanical seal for operating CONSULT FLOWSERVE.


conditions.

Shaft running off centre because of worn bearings Check misalignment and correct if necessary. If
or misalignment. alignment satisfactory check bearings for excessive
wear.
Impeller out of balance resulting in vibration.
Abrasive solids in liquid pumped. Check and CONSULT FLOWSERVE.
Internal misalignment of parts preventing seal ring
and seat from mating properly.

Mechanical seal was run dry. Check mechanical seal condition and source of dry
running and repair.

Internal misalignment due to improper repairs Check method of assembly, possible damage or
causing impeller to rub. state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.

Excessive thrust caused by a mechanical failure Check wear condition of impeller, its clearances and
inside the pump. liquid passages.
Excessive grease in ball bearings. Check method of regreasing.

Lack of lubrication for bearings. Check hours run since last change of lubricant, the
schedule and its basis.

Improper installation of bearings (damage during Check method of assembly, possible damage or
assembly, incorrect assembly, wrong type of state of cleanliness during assembly and type of
bearing etc). bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.

Damaged bearings due to contamination. Check contamination source and replace damaged
bearings.

C. MOTOR ELECTRICAL PROBLEMS


Wrong direction of rotation. Reverse 2 phases at motor terminal box.

Page 42 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

7 FAULTS; CAUSES AND REMEDIES


FAULT SYMPTOM
P u m p o v e r h e a ts a n d s e i z e s
Bearings have short life
Pum p vi b ra t es o r i s noi sy

Mechanical seal has short life

Me cha ni ca l se al lea ks exc es si ve ly

Pump re qui res e xc es si ve p ow er

P u m p l o s e s p r i m e a f t e r s ta r t i n g

Insufficient pressure developed

In suf fi ci ent c apac ity del ive r ed

Pump does not deliver liquid



PROBABLE CAUSES POSSIBLE REMEDIES
Motor running on 2 phases only. Check supply and fuses.
Motor running too slow. Check motor terminal box connections and voltage.

Page 43 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8 PARTS LIST AND DRAWINGS


8.1 Centerline Discharge, Single Volute

8.1.1 Parts list

Ref no Description 3854 Oil Filter Plug


1100 Casing 3855 Constant Level Oiler
1221 Casing Cover 3862 Lubricating Disk Thrower
1500.1 Casing Wear ring 4132 Neck Bush
1500.2 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4330.1 Labyrinth Ring
2200 Impeller 4330.2 Labyrinth Ring
2300.1 Impeller Wear Ring 4510 Gasket
2300.2 Impeller Wear Ring 4590 Gasket
2430 Throttling Sleeve 4610.1 O Ring
2540.1 Deflector 4610.2 O Ring
2540.2 Deflector 6541 Lockwasher
2912 Impeller Nut 6572.2 Stud
3010 Anti-Friction Bearing 6572.1 Stud
3014 Thrust Roller Bearing 6581.1 Hexagon Nut
3130 Bearing Bracket 6581.2 Hexagon Nut
3240 Intermediate Bearing Sleeve 6700.1 Key
3260 Bearing Cover 6700.2 Key
3712 Bearing Nut

Page 44 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.2 Tangential Discharge , Single Volute

8.2.1 Parts list

Ref no Description 3855 Constant Level Oiler


1100 Casing 3862 Lubricating Disk Thrower
1221 Casing Cover 4132 Neck Bush
1500 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4330.1 Labyrinth Ring
2200 Impeller 4330.2 Labyrinth Ring
2300 Impeller Wear Ring 4510 Gasket
2430 Throttling Sleeve 4590 Gasket
2540.1 Deflector 4610.1 O Ring
2540.2 Deflector 4610.2 O Ring
2912 Impeller Nut 6541 Lockwasher
3010 Anti-Friction Bearing 6572.2 Stud
3014 Thrust Roller Bearing 6572.1 Stud
3130 Bearing Bracket 6581.1 Hexagon Nut
3240 Intermediate Bearing Sleeve 6581.2 Hexagon Nut
3260 Bearing Cover 6700.1 Key
3712 Bearing Nut 6700.2 Key
3854 Oil Filter Plug

Page 45 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.3 Centerline Discharge , Doube Volute

8.3.1 Parts list

Ref no Description 3854 Oil Filter Plug


1100 Casing 3855 Constant Level Oiler
1221 Casing Cover 3862 Lubricating Disk Thrower
1500.1 Casing Wear ring 4132 Neck Bush
1500.2 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4330.1 Labyrinth Ring
2200 Impeller 4330.2 Labyrinth Ring
2300.1 Impeller Wear Ring 4510 Gasket
2300.2 Impeller Wear Ring 4590 Gasket
2430 Throttling Sleeve 4610.1 O Ring
2540.1 Deflector 4610.2 O Ring
2540.2 Deflector 6541 Lockwasher
2912 Impeller Nut 6572.2 Stud
3010 Anti-Friction Bearing 6572.1 Stud
3014 Thrust Roller Bearing 6581.1 Hexagon Nut
3130 Bearing Bracket 6581.2 Hexagon Nut
3240 Intermediate Bearing Sleeve 6700.1 Key
3260 Bearing Cover 6700.2 Key
3712 Bearing Nut

Page 46 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.4 Tangential Discharge , Double Volute

8.4.1 Parts list

Ref no Description 3862 Lubricating Disk Thrower


1100 Casing 4132 Neck Bush
1221 Casing Cover 4200 Mechanical Seal
1500 Casing Wear ring 4330.1 Labyrinth Ring
2100 Shaft 4330.2 Labyrinth Ring
2200 Impeller 4510 Gasket
2300 Impeller Wear Ring 4590 Gasket
2540.1 Deflector 4610.1 O Ring
2540.2 Deflector 4610.2 O Ring
2912 Impeller Nut 6541 Lockwasher
3010 Anti-Friction Bearing 6572.2 Stud
3014 Thrust Roller Bearing 6572.1 Stud
3130 Bearing Bracket 6581.1 Hexagon Nut
3240 Intermediate Bearing Sleeve 6581.2 Hexagon Nut
3260 Bearing Cover 6700.1 Key
3712 Bearing Nut 6700.2 Key
3854 Oil Filter Plug
3855 Constant Level Oiler

Page 47 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.5 Impeller Without Back Wear Ring

8.5.1 Parts list

Ref no Description 3862 Lubricating Disk Thrower


1100 Casing 4132 Neck Bush
1221 Casing Cover 4200 Mechanical Seal
1500 Casing Wear ring 4330.1 Labyrinth Ring
2100 Shaft 4330.2 Labyrinth Ring
2200 Impeller 4510 Gasket
2300 Impeller Wear Ring 4590 Gasket
2540.1 Deflector 4610.1 O Ring
2540.2 Deflector 4610.2 O Ring
2912 Impeller Nut 6541 Lockwasher
3010 Anti-Friction Bearing 6572.2 Stud
3014 Thrust Roller Bearing 6572.1 Stud
3130 Bearing Bracket 6581.1 Hexagon Nut
3240 Intermediate Bearing Sleeve 6581.2 Hexagon Nut
3260 Bearing Cover 6700.1 Key
3712 Bearing Nut 6700.2 Key
3854 Oil Filter Plug
3855 Constant Level Oiler

Page 48 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.6 Inducer Option

8.6.1 Parts list

Ref no Description 3712 Bearing Nut


1100 Casing 3854 Oil Filter Plug
1221 Casing Cover 3855 Constant Level Oiler
1500.1 Casing Wear ring 3862 Lubricating Disk Thrower
1500.2 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4330.1 Labyrinth Ring
2200 Impeller 4330.2 Labyrinth Ring
2215 Inducer 4510 Gasket
2300.1 Impeller Wear Ring 4590 Gasket
2300.2 Impeller Wear Ring 4610.1 O Ring
2430 Throttling Sleeve 4610.2 O Ring
2540.1 Deflector 6541 Lockwasher
2540.2 Deflector 6572.2 Stud
2905 Washer 6572.1 Stud
2912 Impeller Nut 6581.1 Hexagon Nut
3010 Anti-Friction Bearing 6581.2 Hexagon Nut
3014 Thrust Roller Bearing 6700.1 Key
3130 Bearing Bracket 6700.2 Key
3240 Intermediate Bearing Sleeve
3260 Bearing Cover

Page 49 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.7 Coke Crusher Option

8.7.1 Parts list

Ref no Description 3260 Bearing Cover


1100 Casing 3712 Bearing Nut
1221 Casing Cover 3854 Oil Filter Plug
1500.1 Casing Wear ring 3855 Constant Level Oiler
1500.2 Casing Wear ring 3862 Lubricating Disk Thrower
2100 Shaft 4200 Mechanical Seal
2200 Impeller 4330.1 Labyrinth Ring
2215.1 Coke Crusher 4330.2 Labyrinth Ring
1649 Coke Crusher Housing 4510 Gasket
2300.1 Impeller Wear Ring 4590 Gasket
2300.2 Impeller Wear Ring 4610.1 O Ring
2430 Throttling Sleeve 4610.2 O Ring
2540.1 Deflector 6541 Lockwasher
2540.2 Deflector 6572.2 Stud
2905 Washer 6572.1 Stud
2912 Impeller Nut 6581.1 Hexagon Nut
3010 Anti-Friction Bearing 6581.2 Hexagon Nut
3014 Thrust Roller Bearing 6700.1 Key
3130 Bearing Bracket 6700.2 Key
3240 Intermediate Bearing Sleeve

Page 50 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.8 Pure Oil Mist Lubrication

8.8.1 Parts list

Ref no Description 3712 Bearing Nut


1100 Casing 3854 Oil Filter Plug
1221 Casing Cover 3855 Constant Level Oiler
1500.1 Casing Wear ring 4200 Mechanical Seal
1500.2 Casing Wear ring 4330.1 Labyrinth Ring
2100 Shaft 4330.2 Labyrinth Ring
2200 Impeller 4510 Gasket
2300.1 Impeller Wear Ring 4590 Gasket
2300.2 Impeller Wear Ring 4610.1 O Ring
2430 Throttling Sleeve 4610.2 O Ring
2540.1 Deflector 6541 Lockwasher
2540.2 Deflector 6572.2 Stud
2912 Impeller Nut 6572.1 Stud
3010 Anti-Friction Bearing 6581.1 Hexagon Nut
3014 Thrust Roller Bearing 6581.2 Hexagon Nut
3130 Bearing Bracket 6700.1 Key
3240 Intermediate Bearing Sleeve 6700.2 Key
3260 Bearing Cover

Page 51 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.9 Bearing Isolator Option

8.9.1 Parts list

Ref no Description 3712 Bearing Nut


1100 Casing 3854 Oil Filter Plug
1221 Casing Cover 3855 Constant Level Oiler
1500.1 Casing Wear ring 3862 Lubricating Disk Thrower
1500.2 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4300.1 Bearing Isolator
2200 Impeller 4300.2 Bearing Isolator
2300.1 Impeller Wear Ring 4510 Gasket
2300.2 Impeller Wear Ring 4590 Gasket
2430 Throttling Sleeve 6541 Lockwasher
2540.1 Deflector 6572.2 Stud
2540.2 Deflector 6572.1 Stud
2912 Impeller Nut 6581.1 Hexagon Nut
3010 Anti-Friction Bearing 6581.2 Hexagon Nut
3014 Thrust Roller Bearing 6700.1 Key
3130 Bearing Bracket 6700.2 Key
3240 Intermediate Bearing Sleeve
3260 Bearing Cover

Page 52 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.10 Fan Cooled Bearing Housing

8.10.1 Parts list

Ref no Description 3854 Oil Filter Plug


1100 Casing 3855 Constant Level Oiler
1221 Casing Cover 3862 Lubricating Disk Thrower
1500.1 Casing Wear ring 4200 Mechanical Seal
1500.2 Casing Wear ring 4330.1 Labyrinth Ring
2100 Shaft 4330.2 Labyrinth Ring
2200 Impeller 4510 Gasket
2300.1 Impeller Wear Ring 4590 Gasket
2300.2 Impeller Wear Ring 4610.1 O Ring
2430 Throttling Sleeve 4610.2 O Ring
2540.1 Deflector 6541 Lockwasher
2540.2 Deflector 6572.2 Stud
2912 Impeller Nut 6572.1 Stud
3010 Anti-Friction Bearing 6581.1 Hexagon Nut
3014 Thrust Roller Bearing 6581.2 Hexagon Nut
3130 Bearing Bracket 6700.1 Key
3240 Intermediate Bearing Sleeve 6700.2 Key
3260 Bearing Cover 8161 Fan
3712 Bearing Nut

Page 53 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.11 Fan Cooled With Bearing isolator

8.11.1 Parts list

Ref no Description 3712 Bearing Nut


1100 Casing 3854 Oil Filter Plug
1221 Casing Cover 3855 Constant Level Oiler
1500.1 Casing Wear ring 3862 Lubricating Disk Thrower
1500.2 Casing Wear ring 4200 Mechanical Seal
2100 Shaft 4305.1 Bearing Isolator
2200 Impeller 4305.2 Bearing Isolator
2300.1 Impeller Wear Ring 4510 Gasket
2300.2 Impeller Wear Ring 4590 Gasket
2430 Throttling Sleeve 6541 Lockwasher
2510 Spacer Ring 6572.2 Stud
2540.1 Deflector 6572.1 Stud
2540.2 Deflector 6581.1 Hexagon Nut
2912 Impeller Nut 6581.2 Hexagon Nut
3010 Anti-Friction Bearing 6700.1 Key
3014 Thrust Roller Bearing 6700.2 Key
3130 Bearing Bracket 8161 Fan
3240 Intermediate Bearing Sleeve
3260 Bearing Cover

Page 54 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.12 Water Cooled Bearing Housing

3130 Bearing Bracket


3240 Intermediate Bearing Sleeve
3260 Bearing Cover
3712 Bearing Nut
3854 Oil Filter Plug
3855 Constant Level Oiler
3862 Lubricating Disk Thrower
8.12.1 Parts list 4200 Mechanical Seal
Ref no Description 4330.1 Labyrinth Ring
1100 Casing 4330.2 Labyrinth Ring
1221 Casing Cover 4510 Gasket
1500.1 Casing Wear ring 4590 Gasket
1500.2 Casing Wear ring 4610.1 O Ring
2100 Shaft 4610.2 O Ring
2200 Impeller 6541 Lockwasher
2300.1 Impeller Wear Ring 6551 Cooling Device
2300.2 Impeller Wear Ring 6572.2 Stud
2430 Throttling Sleeve 6572.1 Stud
2540.1 Deflector 6581.1 Hexagon Nut
2540.2 Deflector 6581.2 Hexagon Nut
2912 Impeller Nut 6700.1 Key
3010 Anti-Friction Bearing 6700.2 Key
3014 Thrust Roller Bearing

Page 55 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.13 Cooled Casing Cover

8.13.1 Parts list

Ref no Description 3854 Oil Filter Plug


1100 Casing 3855 Constant Level Oiler
1221 Casing Cover 3862 Lubricating Disk Thrower
1500.1 Casing Wear ring 4200 Mechanical Seal
1500.2 Casing Wear ring 4330.1 Labyrinth Ring
2100 Shaft 4330.2 Labyrinth Ring
2200 Impeller 4510 Gasket
2300.1 Impeller Wear Ring 4590 Gasket
2300.2 Impeller Wear Ring 4610.1 O Ring
2430 Throttling Sleeve 4610.2 O Ring
2540.1 Deflector 6541 Lockwasher
2540.2 Deflector 6572.2 Stud
2912 Impeller Nut 6572.1 Stud
3010 Anti-Friction Bearing 6581.1 Hexagon Nut
3014 Thrust Roller Bearing 6581.2 Hexagon Nut
3130 Bearing Bracket 6700.1 Key
3240 Intermediate Bearing Sleeve 6700.2 Key
3260 Bearing Cover
3712 Bearing Nut

Page 56 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

8.15 General arrangement drawing 10.3 Additional sources of information


The typical general arrangement drawing and any
specific drawings required by the contract will be
sent to the Purchaser separately unless the Reference 1:
contract specifically calls for these to be included NPSH for Rotordynamic Pumps: a reference guide,
into the User Instructions. If required, copies of Europump Guide No. 1, Europump & World Pumps,
other drawings sent separately to the Purchaser Elsevier Science, United Kingdom, 1999.
should be obtained from the Purchaser and
retained with these User Instructions Reference 2:
Pumping Manual, 9th edition, T.C. Dickenson,
9 CERTIFICATION Elsevier Advanced Technology, United Kingdom,
Certificates determined from the Contract 1995.
requirements are provided with these instructions
where applicable. Examples are certificates for CE Reference 3:
marking, ATEX marking etc. If required, copies of Pump Handbook, 2nd edition, Igor J. Karassik et al,
other certificates sent separately to the Purchaser McGraw-Hill Inc., New York, 1993.
should be obtained from the Purchaser for retention
with these User Instructions. Reference 4:
ANSI/HI 1.1-1.5
10 OTHER RELEVANT Centrifugal Pumps - Nomenclature, Definitions,
DOCUMENTATION AND MANUALS Application and Operation.

Reference 5:
10.1 Supplementary User Instruction ANSI B31.3 - Process Piping.
manuals
Supplementary instruction determined from the
contract requirements for inclusion into User
Instructions such as for a driver, instrumentation,
controller, sub-driver, seals, sealant system,
mounting component etc are included under this
section. If further copies of these are required they
should be obtained from the purchaser for retention
with these User Instructions.

10.2 Change notes


If any changes, agreed with Flowserve, are made
to the product after its supply, a record of the
details should be maintained with these User
Instructions.

Page 57 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

NOTES:

Page 58 of 59
HPX-H AND HPX-MP USER INSTRUCTIONS ENGLISH 87900021 - 06/14

FLOWSERVE REGIONAL
Your Flowserve factory contacts: SALES OFFICES:

Service & Warranty: USA and Canada


Flowserve Flow Solutions Group - Italy Flowserve Corporation
Worthington S.r.l. 5215 North OConnor Blvd.,
Via Rossini, 90/92
Suite 2300
20033 Desio (MB) - Italy
Irving, Texas 75039-5421 USA
Telephone (24 hours) +39 0362 6121
Telephone 1 972 443 6500
Fax +39 0362 628882
Fax 1 972 443 6800
+39 0362 620750

Spare Parts & Repair : Europe, Middle East, Africa


Flowserve Flow Solutions Group - Italy Worthing S.P.A.
Worthington S.r.l. Flowserve Corporation
S.S. Sannitica, 87 Km 19 Via Rossini 90/92
81025 Marcianise (CE) - Italy 20033 Desio (Milan) Italy
Telephone (24 hours) +39 0823 634111 Telephone 39 0362 6121
Fax +39 0823 821747 Fax 39 0362 303396
+39 0823 634218
Latin America and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Local Flowserve factory representatives: Houston, Texas 77008 USA
Telephone 1 713 803 4434
Fax 1 713 803 4497

Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone +65 6771 0600
Fax +65 6779 4607

To find your local Flowserve representative please


use the Sales Support Locator System found at
www.flowserve.com